Surgical instruments comprising button circuits

ABSTRACT

A surgical instrument is disclosed comprising an actuator and circuitry mounted on and/or embedded in the actuator.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/778,572, entitled SURGICAL INSTRUMENT SYSTEMS,filed Dec. 12, 2018, the disclosure of which is incorporated byreference herein in its entirety. This application claims the benefit ofU.S. Provisional Patent Application Ser. No. 62/750,529, entitled METHODFOR OPERATING A POWERED ARTICULATING MULTI-CLIP APPLIER, filed Oct. 25,2018, of U.S. Provisional Patent Application Ser. No. 62/750,539,entitled SURGICAL CLIP APPLIER, filed Oct. 25, 2018, and of U.S.Provisional Patent Application Ser. No. 62/750,555, entitled SURGICALCLIP APPLIER, filed Oct. 25, 2018, the disclosures of which areincorporated by reference herein in their entireties. This applicationclaims the benefit of U.S. Provisional Patent Application Ser. No.62/659,900, entitled METHOD OF HUB COMMUNICATION, filed Apr. 19, 2018,the disclosure of which is incorporated by reference herein in itsentirety. This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/665,128, entitled MODULAR SURGICAL INSTRUMENTS,filed May 1, 2018, of U.S. Provisional Patent Application Ser. No.62/665,129, entitled SURGICAL SUTURING SYSTEMS, filed May 1, 2018, ofU.S. Provisional Patent Application Ser. No. 62/665,134, entitledSURGICAL CLIP APPLIER, filed May 1, 2018, of U.S. Provisional PatentApplication Ser. No. 62/665,139, entitled SURGICAL INSTRUMENTSCOMPRISING CONTROL SYSTEMS, filed May 1, 2018, of U.S. ProvisionalPatent Application Ser. No. 62/665,177, entitled SURGICAL INSTRUMENTSCOMPRISING HANDLE ARRANGEMENTS, filed May 1, 2018, and of U.S.Provisional Patent Application Ser. No. 62/665,192, entitled SURGICALDISSECTORS, filed May 1, 2018, the disclosures of which are incorporatedby reference herein in their entireties. This application claims thebenefit of U.S. Provisional Patent Application Ser. No. 62/649,291,entitled USE OF LASER LIGHT AND RED-GREEN-BLUE COLORATION TO DETERMINEPROPERTIES OF BACK SCATTERED LIGHT, filed Mar. 28, 2018, of U.S.Provisional Patent Application Ser. No. 62/649,294, entitled DATASTRIPPING METHOD TO INTERROGATE PATIENT RECORDS AND CREATE ANONYMIZEDRECORD, filed Mar. 28, 2018, of U.S. Provisional Patent Application Ser.No. 62/649,296, entitled ADAPTIVE CONTROL PROGRAM UPDATES FOR SURGICALDEVICES, filed Mar. 28, 2018, of U.S. Provisional Patent ApplicationSer. No. 62/649,300, entitled SURGICAL HUB SITUATIONAL AWARENESS, filedMar. 28, 2018, of U.S. Provisional Patent Application Ser. No.62/649,302, entitled INTERACTIVE SURGICAL SYSTEMS WITH ENCRYPTEDCOMMUNICATION CAPABILITIES, filed Mar. 28, 2018, of U.S. ProvisionalPatent Application Ser. No. 62/649,307, entitled AUTOMATIC TOOLADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS, filed Mar. 28, 2018,of U.S. Provisional Patent Application Ser. No. 62/649,309, entitledSURGICAL HUB SPATIAL AWARENESS TO DETERMINE DEVICES IN OPERATINGTHEATER, filed Mar. 28, 2018, of U.S. Provisional Patent ApplicationSer. No. 62/649,310, entitled COMPUTER IMPLEMENTED INTERACTIVE SURGICALSYSTEMS, filed Mar. 28, 2018, of U.S. Provisional Patent ApplicationSer. No. 62/649,313, entitled CLOUD INTERFACE FOR COUPLED SURGICALDEVICES, filed Mar. 28, 2018, of U.S. Provisional Patent ApplicationSer. No. 62/649,315, entitled DATA HANDLING AND PRIORITIZATION IN ACLOUD ANALYTICS NETWORK, filed Mar. 28, 2018, of U.S. Provisional PatentApplication Ser. No. 62/649,320, entitled DRIVE ARRANGEMENTS FORROBOT-ASSISTED SURGICAL PLATFORMS, filed Mar. 28, 2018, of U.S.Provisional Patent Application Ser. No. 62/649,323, entitled SENSINGARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS, filed Mar. 28, 2018,of U.S. Provisional Patent Application Ser. No. 62/649,327, entitledCLOUD-BASED MEDICAL ANALYTICS FOR SECURITY AND AUTHENTICATION TRENDS ANDREACTIVE MEASURES, filed Mar. 28, 2018, and of U.S. Provisional PatentApplication Ser. No. 62/649,333, entitled CLOUD-BASED MEDICAL ANALYTICSFOR CUSTOMIZATION AND RECOMMENDATIONS TO A USER, filed Mar. 28, 2018,the disclosures of which are incorporated by reference herein in theirentireties. This application claims the benefit of U.S. ProvisionalPatent Application Ser. No. 62/611,339, entitled ROBOT ASSISTED SURGICALPLATFORM, filed Dec. 28, 2017, of U.S. Provisional Patent ApplicationSer. No. 62/611,340, entitled CLOUD-BASED MEDICAL ANALYTICS, filed Dec.28, 2017, and of U.S. Provisional Patent Application Ser. No.62/611,341, entitled INTERACTIVE SURGICAL PLATFORM, filed Dec. 28, 2017,the disclosures of which are incorporated by reference herein in theirentireties.

BACKGROUND

The present disclosure relates to surgical systems and, in variousarrangements, to grasping instruments that are designed to grasp thetissue of a patient, dissecting instruments configured to manipulate thetissue of a patient, clip appliers configured to clip the tissue of apatient, and suturing instruments configured to suture the tissue of apatient, among others.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 illustrates a surgical system comprising a handle and severalshaft assemblies—each of which are selectively attachable to the handlein accordance with at least one embodiment;

FIG. 2 is an elevational view of the handle and one of the shaftassemblies of the surgical system of FIG. 1;

FIG. 3 is a partial cross-sectional perspective view of the shaftassembly of FIG. 2;

FIG. 4 is another partial cross-sectional perspective view of the shaftassembly of FIG. 2;

FIG. 5 is a partial exploded view of the shaft assembly of FIG. 2;

FIG. 6 is a partial cross-sectional elevational view of the shaftassembly of FIG. 2;

FIG. 7 is an elevational view of a drive module of the handle of FIG. 1;

FIG. 8 is a cross-sectional perspective view of the drive module of FIG.7;

FIG. 9 is an end view of the drive module of FIG. 7;

FIG. 10 is a partial cross-sectional view of the interconnection betweenthe handle and shaft assembly of FIG. 2 in a locked configuration;

FIG. 11 is a partial cross-sectional view of the interconnection betweenthe handle and shaft assembly of FIG. 2 in an unlocked configuration;

FIG. 12 is a cross-sectional perspective view of a motor and a speedreduction gear assembly of the drive module of FIG. 7;

FIG. 13 is an end view of the speed reduction gear assembly of FIG. 12;

FIG. 14 is a partial perspective view of an end effector of the shaftassembly of FIG. 2 in an open configuration;

FIG. 15 is a partial perspective view of the end effector of FIG. 14 ina closed configuration;

FIG. 16 is a partial perspective view of the end effector of FIG. 14articulated in a first direction;

FIG. 17 is a partial perspective view of the end effector of FIG. 14articulated in a second direction;

FIG. 18 is a partial perspective view of the end effector of FIG. 14rotated in a first direction;

FIG. 19 is a partial perspective view of the end effector of FIG. 14rotated in a second direction;

FIG. 20 is a partial cross-sectional perspective view of the endeffector of FIG. 14 detached from the shaft assembly of FIG. 2;

FIG. 21 is an exploded view of the end effector of FIG. 14 illustratedwith some components removed;

FIG. 22 is an exploded view of a distal attachment portion of the shaftassembly of FIG. 2;

FIG. 22A is an exploded view of the distal portion of the shaft assemblyof FIG. 2 illustrated with some components removed;

FIG. 23 is another partial cross-sectional perspective view of the endeffector of FIG. 14 detached from the shaft assembly of FIG. 2;

FIG. 24 is a partial cross-sectional perspective view of the endeffector of FIG. 14 attached to the shaft assembly of FIG. 2;

FIG. 25 is a partial cross-sectional perspective view of the endeffector of FIG. 14 attached to the shaft assembly of FIG. 2;

FIG. 26 is another partial cross-sectional perspective view of the endeffector of FIG. 14 attached to the shaft assembly of FIG. 2;

FIG. 27 is a partial cross-sectional view of the end effector of FIG. 14attached to the shaft assembly of FIG. 2 depicting a first, second, andthird clutch of the end effector;

FIG. 28 depicts the first clutch of FIG. 27 in an unactuated condition;

FIG. 29 depicts the first clutch of FIG. 27 in an actuated condition;

FIG. 30 depicts the second clutch of FIG. 27 in an unactuated condition;

FIG. 31 depicts the second clutch of FIG. 27 in an actuated condition;

FIG. 32 depicts the third clutch of FIG. 27 in an unactuated condition;

FIG. 33 depicts the third clutch of FIG. 27 in an actuated condition;

FIG. 34 depicts the second and third clutches of FIG. 27 in theirunactuated conditions and the end effector of FIG. 14 locked to theshaft assembly of FIG. 2;

FIG. 35 depicts the second clutch of FIG. 27 in its unactuated conditionand the third clutch of FIG. 27 in its actuated condition;

FIG. 36 depicts the second and third clutches of FIG. 27 in theiractuated conditions and the end effector of FIG. 14 unlocked from theshaft assembly of FIG. 2;

FIG. 37 is a partial cross-sectional view of a shaft assembly inaccordance with at least one alternative embodiment comprising sensorsconfigured to detect the conditions of the first, second, and thirdclutches of FIG. 27;

FIG. 38 is a partial cross-sectional view of a shaft assembly inaccordance with at least one alternative embodiment comprising sensorsconfigured to detect the conditions of the first, second, and thirdclutches of FIG. 27;

FIG. 39 depicts the first and second clutches of FIG. 38 in theirunactuated conditions and a sensor in accordance with at least onealternative embodiment;

FIG. 40 depicts the second and third clutches of FIG. 38 in theirunactuated conditions and a sensor in accordance with at least onealternative embodiment;

FIG. 41 is a partial cross-sectional view of a shaft assembly inaccordance with at least one embodiment;

FIG. 42 is a partial cross-sectional view of the shaft assembly of FIG.41 comprising a clutch illustrated in an unactuated condition;

FIG. 43 is a partial cross-sectional view of the shaft assembly of FIG.41 illustrating the clutch in an actuated condition;

FIG. 44 is a partial cross-sectional view of a shaft assembly inaccordance with at least one embodiment comprising first and secondclutches illustrated in an unactuated condition;

FIG. 45 is a perspective view of the handle drive module of FIG. 7 andone of the shaft assemblies of the surgical system of FIG. 1;

FIG. 46 is another perspective view of the handle drive module of FIG. 7and the shaft assembly of FIG. 45;

FIG. 47 is a partial cross-sectional view of the shaft assembly of FIG.45 attached to the handle of FIG. 1;

FIG. 48 is another partial cross-sectional view of the shaft assembly ofFIG. 45 attached to the handle of FIG. 1;

FIG. 49 is a partial cross-sectional perspective view of the shaftassembly of FIG. 45;

FIG. 50 is a schematic of the control system of the surgical system ofFIG. 1;

FIG. 51 is an elevational view of the handle and one of the shaftassemblies of the surgical system of FIG. 1;

FIG. 52 is a perspective view of the handle of FIG. 1 and the shaftassembly of FIG. 2;

FIG. 53 is a partial top plan view of the handle of FIG. 1 and the shaftassembly of FIG. 2;

FIG. 54 is a partial elevational view of the handle of FIG. 1 and theshaft assembly of FIG. 2;

FIG. 55 is a perspective view of the drive module of FIG. 7 and a powermodule of FIG. 1;

FIG. 56 is a perspective view of the drive module of FIG. 7 and thepower module of FIG. 55;

FIG. 57 is an elevational view of the drive module of FIG. 7 and thepower module of FIG. 55 attached to a side battery port of the drivemodule;

FIG. 58 is a partial cross-sectional view of the connection between theside battery port of the drive module of FIG. 7 and the power module ofFIG. 55;

FIG. 59 is an elevational view of the handle drive module of FIG. 7, thepower module of FIG. 45 attached to a proximal battery port of thehandle drive module, and the shaft assembly of FIG. 45 attached to thedrive module;

FIG. 60 is a top view of the drive module of FIG. 7 and the power moduleof FIG. 45 attached to the proximal battery port;

FIG. 61 is an elevational view of the drive module of FIG. 7 and thepower module of FIG. 45 attached to the proximal battery port;

FIG. 62 is a perspective view of the drive module of FIG. 7 and thepower module of FIG. 45 attached to the proximal battery port;

FIG. 63 is a perspective view of the power module of FIG. 45 detachedfrom the drive module of FIG. 7;

FIG. 64 is another perspective view of the power module of FIG. 45detached from the drive module of FIG. 7;

FIG. 65 is an elevational view of the power module of FIG. 45 attachedto the proximal battery port of the drive module of FIG. 7;

FIG. 66 is a partial cross-sectional view of the connection betweenproximal battery port of the drive module of FIG. 7 and the power moduleof FIG. 45;

FIG. 67 is an elevational view of the power module of FIG. 55 attachedto the proximal battery port of the drive module of FIG. 7;

FIG. 68 is a partial cross-sectional view of the connection between theproximal battery port of the drive module of FIG. 7 and the power moduleof FIG. 55;

FIG. 69 is an elevational view of an attempt to connect the power moduleof FIG. 45 to the side battery port of the drive module of FIG. 7;

FIG. 70 is a cross-sectional detail view of an attempt to connect thepower module of FIG. 45 to the side battery port of the drive module ofFIG. 7;

FIG. 71 is a perspective view of the power module of FIG. 45 attached tothe proximal battery port of the drive module of FIG. 7 and the powermodule of FIG. 55 attached to the side battery port;

FIG. 72 is a cross-sectional view of the power module of FIG. 45attached to the proximal battery port of the drive module of FIG. 7 andthe power module of FIG. 55 attached to the side battery port;

FIG. 73 is a perspective view of a portion of a surgical instrumentcomprising selectively attachable modular components in accordance withat least one aspect of the present disclosure;

FIG. 74 illustrates an electrical architecture of the surgicalinstrument of FIG. 73 in accordance with at least one aspect of thepresent disclosure;

FIG. 75 is a partial cross-sectional perspective view of a handle of thesurgical instrument of FIG. 73 in accordance with at least one aspect ofthe present disclosure;

FIG. 76 is a perspective view of a system of magnetic elements arrangedon the handle and a shaft of the surgical instrument of FIG. 73 inaccordance with at least one aspect of the present disclosure;

FIG. 77 is a perspective view of a system of magnetic elements arrangedon the handle and the shaft of the surgical instrument of FIG. 73 inaccordance with at least one aspect of the present disclosure;

FIG. 78 is a perspective view of the system of magnetic elements of FIG.77 aligning the shaft with the handle of the surgical instrument inaccordance with at least one aspect of the present disclosure;

FIG. 79 is a perspective view of a flex circuit for use in the surgicalinstrument of FIG. 73 in accordance with at least one aspect of thepresent disclosure;

FIG. 79A is a detail perspective view of a primary strain relief portionof the flex circuit of FIG. 79 in accordance with at least one aspect ofthe present disclosure;

FIG. 79B is a detail perspective view of a secondary strain reliefportion of the flex circuit of FIG. 79 in accordance with at least oneaspect of the present disclosure;

FIG. 79C is a detail perspective view of control circuit componentsincorporated into a flexible plastic of the flex circuit of FIG. 79 inaccordance with at least one aspect of the present disclosure;

FIG. 80 is a perspective view of a flex circuit for use in combinationwith the flex circuit of FIG. 79 in accordance with at least one aspectof the present disclosure;

FIG. 81A is a perspective view of the flex circuit of FIG. 79 prior tobeing electrically coupled with the flex circuit of FIG. 80 inaccordance with at least one aspect of the present disclosure;

FIG. 81B is a perspective view of the flex circuit of FIG. 79electrically coupled to the flex circuit of FIG. 80 in accordance withat least one aspect of the present disclosure;

FIG. 82 is an elevational view of a surgical instrument in accordancewith at least one embodiment;

FIG. 82A is a partial detail view of the surgical instrument of FIG. 82;

FIG. 82B is a partial detail view of the surgical instrument of FIG. 82illustrating a probe inserted into a handle of the surgical instrument;

FIG. 82C is a perspective view of a trocar in accordance with at leastone embodiment configured to facilitate the insertion of the surgicalinstrument of FIG. 82, for example, into a patient;

FIG. 83 is a perspective view of a drive system of the surgicalinstrument of FIG. 82;

FIG. 84 is a perspective view of a drive system in accordance with atleast one embodiment;

FIG. 85 is a perspective view of a strain gage of the surgicalinstrument of FIG. 82;

FIG. 85A depicts the strain gage of FIG. 85 in an elongated condition;

FIG. 85B depicts the strain gage of FIG. 85 in a contracted condition;

FIG. 85C illustrates a Wheatstone bridge comprising a strain gage inaccordance with at least one embodiment;

FIG. 86 is a perspective view of one half of a handle housing of thesurgical instrument of FIG. 82;

FIG. 87 is a partial perspective view of circuit boards in the handle ofFIG. 86;

FIG. 88 is a partial cross-sectional view of a surgical instrument inaccordance with at least one embodiment;

FIG. 89 is a partial detail view of an electrical interface within thesurgical instrument of FIG. 88;

FIG. 90 is a perspective view of a handle in accordance with at leastone embodiment;

FIG. 91 is a perspective view of a button shell of the handle of FIG.90;

FIG. 92 is a perspective view of another button shell of the handle ofFIG. 90;

FIG. 93 is a perspective view of another button shell of the handle ofFIG. 90;

FIG. 94 is a cross-sectional view of a button shell in accordance withat least one embodiment;

FIG. 95 is a cross-sectional view of a button shell in accordance withat least one embodiment;

FIG. 96 is a perspective view of a surgical instrument handle inaccordance with at least one embodiment;

FIG. 97 is a perspective view of a surgical instrument handle inaccordance with at least one embodiment;

FIG. 98 is a perspective view of a surgical instrument handle inaccordance with at least one embodiment;

FIG. 99 is an icon displayable on a surgical instrument in accordancewith at least one embodiment;

FIG. 100 is an icon displayable on a surgical instrument in accordancewith at least one embodiment;

FIG. 101 is an icon displayable on a surgical instrument in accordancewith at least one embodiment;

FIG. 101A illustrates a handle flexible circuit and a shaft flexiblecircuit of a surgical instrument, in accordance with at least oneembodiment;

FIG. 101B illustrates a connection between the handle flexible circuitand the shaft flexible circuit of FIG. 101A;

FIG. 102 illustrates a control circuit of a surgical instrument, inaccordance with at least one embodiment;

FIG. 103 illustrates timing diagrams associated with the control circuitof FIG. 102, in accordance with at least one embodiment;

FIG. 104 illustrates a control circuit of a surgical instrument, inaccordance with at least one embodiment;

FIG. 104A illustrates a control circuit configured to indicate the powerbeing delivered to an electric motor, in accordance with at least oneembodiment;

FIG. 104B illustrates a graduated display in communication with thecontrol circuit of FIG. 104A, in accordance with at least oneembodiment;

FIG. 104C illustrates a surgical instrument comprising a handle, inaccordance with at least one embodiment;

FIG. 105 illustrates a surgical system, in accordance with at least oneembodiment;

FIG. 106 illustrates a schematic diagram representative of current andsignal paths of the surgical system of FIG. 105, in accordance with atleast one embodiment;

FIG. 107 illustrates a graph showing a relationship between a continuitylevel of a patient and a level of electrosurgical power supplied by thesurgical system of FIG. 105, in accordance with at least one embodiment;

FIG. 108 illustrates a flexible circuit of a surgical instrument, inaccordance with at least one embodiment;

FIG. 109 illustrates a cross-section of the flexible circuit of FIG.108;

FIG. 110 illustrates a flexible circuit of a surgical instrument, inaccordance with at least one embodiment;

FIG. 111 illustrates a cross-section of the flexible circuit of FIG.110;

FIG. 111A illustrates a flexible circuit of a surgical instrument, inaccordance with at least one embodiment;

FIG. 112 illustrates a control circuit of a surgical instrument, inaccordance with at least one embodiment;

FIG. 113 illustrates a method for identifying a degradation or failureof components of a surgical instrument, in accordance with at least oneembodiment;

FIG. 114 illustrates a graph showing frequency component signals ofacoustical signatures of components of a surgical instrument, inaccordance with at least one embodiment;

FIG. 115 illustrates components associated with the frequency componentsignals of FIG. 114;

FIG. 116 illustrates a method for identifying a degradation or failureof drive components of a surgical instrument, in accordance with atleast one embodiment;

FIG. 117 illustrates a graph showing a relationship between motorcurrent draw and frequency component signals of the motor of a surgicalinstrument, in accordance with at least one embodiment;

FIG. 118 illustrates a method for adjusting a motor control algorithm ofa surgical instrument, in accordance with at least one embodiment;

FIG. 119 illustrates an environment of a surgical procedure, inaccordance with at least one embodiment;

FIG. 120 illustrates a monopolar surgical instrument, in accordance withat least one embodiment;

FIGS. 121 and 122 illustrate electrical terminations of the monopolarsurgical instrument of FIG. 120;

FIG. 123 illustrates a graph showing a relationship between leakagecurrent and distances between surgical instruments, in accordance withat least one aspect of the present disclosure;

FIG. 124 illustrates a graph showing direct current (DC) output voltagethresholds for different types of surgical instrument contact, inaccordance with at least one embodiment;

FIG. 125 illustrates a powered surgical instrument, in accordance withat least one embodiment;

FIG. 126 illustrates a graph showing electrical potential associatedwith the powered surgical instrument of FIG. 125, in accordance with atleast one embodiment;

FIG. 127 illustrates an active transmission and sensing scheme utilizedby a surgical instrument, in accordance with at least one embodiment;

FIG. 128 illustrates a graph showing signals transmitted and received bythe surgical instrument of FIG. 127;

FIG. 129 illustrates a graph showing proximity measurements associatedwith the surgical instrument of FIG. 127;

FIG. 130 illustrates a passive sensing scheme utilized by a surgicalinstrument, in accordance with at least one embodiment;

FIG. 131 illustrates a primary magnetic field associated with thesurgical instrument of FIG. 130 in an unaffected condition;

FIG. 132 illustrates a primary magnetic field associated with thesurgical instrument of FIG. 130 in an affected condition;

FIG. 133 illustrates a graph which showing Hall current associated withthe surgical instrument of FIG. 130, in accordance with at least oneembodiment;

FIGS. 134 and 135 illustrate a passive sensing scheme utilized by asurgical instrument, in accordance with at least one embodiment;

FIG. 136 illustrates a schematic of a surgical instrument, in accordancewith at least one embodiment;

FIG. 137 illustrates a graph which showing induced current measured by acurrent sensor of the surgical instrument of FIG. 136, in accordancewith at least one embodiment;

FIG. 138 illustrates a surgical instrument in accordance with at leastone embodiment illustrated with components removed;

FIG. 139 illustrates an electrical circuit of the surgical instrument ofFIG. 138;

FIG. 140 illustrates a graph showing relationships between altitude,atmospheric pressure and electrical power utilized by a surgicalinstrument, in accordance with at least one embodiment;

FIG. 141 illustrates a method for predicting an occurrence of apredefined temperature threshold being exceeded, in accordance with atleast one embodiment; and

FIG. 142 illustrates a graph showing a relationship between a sensedtemperature, an approximated temperature, and an energy usage of asurgical instrument, in accordance with at least one embodiment.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. patentapplications that were filed on Dec. 14, 2018 which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 16/220,281, entitled SURGICAL        INSTRUMENT WITH A HARDWARE-ONLY CONTROL CIRCUIT, now U.S. Patent        Application Publication No. 2019/0201025;    -   U.S. patent application Ser. No. 16/220,301, entitled SURGICAL        INSTRUMENT WITH ACOUSTIC-BASED MOTOR CONTROL, now U.S. Patent        Application Publication No. 2019/0201027;    -   U.S. patent application Ser. No. 16/220,313, entitled SURGICAL        INSTRUMENT COMPRISING A PLURALITY OF DRIVE SYSTEMS, now U.S.        Patent Application Publication No. 2019/0201030;    -   U.S. patent application Ser. No. 16/220,296, entitled SURGICAL        INSTRUMENT COMPRISING A CONTROL CIRCUIT, now U.S. Patent        Application Publication No. 2019/0201026;    -   U.S. patent application Ser. No. 16/220,318, entitled SURGICAL        INSTRUMENT COMPRISING A CONTROL SYSTEM THAT USES INPUT FROM A        STRAIN GAGE CIRCUIT, now U.S. Patent Application Publication No.        2019/0201029;    -   U.S. patent application Ser. No. 16/220,273, entitled SURGICAL        INSTRUMENT WITH A SENSING ARRAY, now U.S. Pat. No. 11,324,557;        and    -   U.S. patent application Ser. No. 16/220,280, entitled SURGICAL        INSTRUMENT WITH ENVIRONMENT SENSING, now U.S. Patent Application        Publication No. 2019/0201024.

Applicant of the present application owns the following U.S. Provisionalpatent applications, filed on Dec. 12, 2018, each of which is hereinincorporated by reference in its entirety:

-   -   U.S. Provisional Patent Application Ser. No. 62/778,571,        entitled SURGICAL INSTRUMENT SYSTEMS;    -   U.S. Provisional Patent Application Ser. No. 62/778,572,        entitled SURGICAL INSTRUMENT SYSTEMS; and    -   U.S. Provisional Patent Application Ser. No. 62/778,573,        entitled SURGICAL INSTRUMENT SYSTEMS.

Applicant of the present application owns the following U.S. patentapplications that were filed on Oct. 26, 2018 which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 16/172,130, entitled CLIP        APPLIER COMPRISING INTERCHANGEABLE CLIP RELOADS;    -   U.S. patent application Ser. No. 16/172,066, entitled CLIP        APPLIER COMPRISING A MOVABLE CLIP MAGAZINE;    -   U.S. patent application Ser. No. 16/172,078, entitled CLIP        APPLIER COMPRISING A ROTATABLE CLIP MAGAZINE;    -   U.S. patent application Ser. No. 16/172,087, entitled CLIP        APPLIER COMPRISING CLIP ADVANCING SYSTEMS;    -   U.S. patent application Ser. No. 16/172,094, entitled CLIP        APPLIER COMPRISING A CLIP CRIMPING SYSTEM;    -   U.S. patent application Ser. No. 16/172,128, entitled CLIP        APPLIER COMPRISING A RECIPROCATING CLIP ADVANCING MEMBER;    -   U.S. patent application Ser. No. 16/172,168, entitled CLIP        APPLIER COMPRISING A MOTOR CONTROLLER;    -   U.S. patent application Ser. No. 16/172,164, entitled SURGICAL        SYSTEM COMPRISING A SURGICAL TOOL AND A SURGICAL HUB; and    -   U.S. patent application Ser. No. 16/172,303, entitled METHOD FOR        OPERATING A POWERED ARTICULATING MULTI-CLIP APPLIER.

Applicant of the present application owns the following U.S. patentapplications that were filed on Oct. 26, 2018 which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 16/172,328, entitled METHOD OF        HUB COMMUNICATION WITH SURGICAL INSTRUMENT SYSTEMS;    -   U.S. patent application Ser. No. 16/172,280, entitled METHOD FOR        PRODUCING A SURGICAL INSTRUMENT COMPRISING A SMART ELECTRICAL        SYSTEM;    -   U.S. patent application Ser. No. 16/172,219, entitled METHOD OF        HUB COMMUNICATION WITH SURGICAL INSTRUMENT SYSTEMS;    -   U.S. patent application Ser. No. 16/172,248, entitled METHOD FOR        COMMUNICATING WITH SURGICAL INSTRUMENT SYSTEMS;    -   U.S. patent application Ser. No. 16/172,198, entitled METHOD OF        HUB COMMUNICATION WITH SURGICAL INSTRUMENT SYSTEMS; and    -   U.S. patent application Ser. No. 16/172,155, entitled METHOD OF        HUB COMMUNICATION WITH SURGICAL INSTRUMENT SYSTEMS.

Applicant of the present application owns the following U.S. patentapplications that were filed on Aug. 24, 2018 which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 16/112,129, entitled SURGICAL        SUTURING INSTRUMENT CONFIGURED TO MANIPULATE TISSUE USING        MECHANICAL AND ELECTRICAL POWER;    -   U.S. patent application Ser. No. 16/112,155, entitled SURGICAL        SUTURING INSTRUMENT COMPRISING A CAPTURE WIDTH WHICH IS LARGER        THAN TROCAR DIAMETER;    -   U.S. patent application Ser. No. 16/112,168, entitled SURGICAL        SUTURING INSTRUMENT COMPRISING A NON-CIRCULAR NEEDLE;    -   U.S. patent application Ser. No. 16/112,180, entitled ELECTRICAL        POWER OUTPUT CONTROL BASED ON MECHANICAL FORCES;    -   U.S. patent application Ser. No. 16/112,193, entitled REACTIVE        ALGORITHM FOR SURGICAL SYSTEM;    -   U.S. patent application Ser. No. 16/112,099, entitled SURGICAL        INSTRUMENT COMPRISING AN ADAPTIVE ELECTRICAL SYSTEM;    -   U.S. patent application Ser. No. 16/112,112, entitled CONTROL        SYSTEM ARRANGEMENTS FOR A MODULAR SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 16/112,119, entitled ADAPTIVE        CONTROL PROGRAMS FOR A SURGICAL SYSTEM COMPRISING MORE THAN ONE        TYPE OF CARTRIDGE;    -   U.S. patent application Ser. No. 16/112,097, entitled SURGICAL        INSTRUMENT SYSTEMS COMPRISING BATTERY ARRANGEMENTS;    -   U.S. patent application Ser. No. 16/112,109, entitled SURGICAL        INSTRUMENT SYSTEMS COMPRISING HANDLE ARRANGEMENTS;    -   U.S. patent application Ser. No. 16/112,114, entitled SURGICAL        INSTRUMENT SYSTEMS COMPRISING FEEDBACK MECHANISMS;    -   U.S. patent application Ser. No. 16/112,117, entitled SURGICAL        INSTRUMENT SYSTEMS COMPRISING LOCKOUT MECHANISMS;    -   U.S. patent application Ser. No. 16/112,095, entitled SURGICAL        INSTRUMENTS COMPRISING A LOCKABLE END EFFECTOR SOCKET;    -   U.S. patent application Ser. No. 16/112,121, entitled SURGICAL        INSTRUMENTS COMPRISING A SHIFTING MECHANISM;    -   U.S. patent application Ser. No. 16/112,151, entitled SURGICAL        INSTRUMENTS COMPRISING A SYSTEM FOR ARTICULATION AND ROTATION        COMPENSATION;    -   U.S. patent application Ser. No. 16/112,154, entitled SURGICAL        INSTRUMENTS COMPRISING A BIASED SHIFTING MECHANISM;    -   U.S. patent application Ser. No. 16/112,226, entitled SURGICAL        INSTRUMENTS COMPRISING AN ARTICULATION DRIVE THAT PROVIDES FOR        HIGH ARTICULATION ANGLES;    -   U.S. patent application Ser. No. 16/112,062, entitled SURGICAL        DISSECTORS AND MANUFACTURING TECHNIQUES;    -   U.S. patent application Ser. No. 16/112,098, entitled SURGICAL        DISSECTORS CONFIGURED TO APPLY MECHANICAL AND ELECTRICAL ENERGY;    -   U.S. patent application Ser. No. 16/112,237, entitled SURGICAL        CLIP APPLIER CONFIGURED TO STORE CLIPS IN A STORED STATE;    -   U.S. patent application Ser. No. 16/112,245, entitled SURGICAL        CLIP APPLIER COMPRISING AN EMPTY CLIP CARTRIDGE LOCKOUT;    -   U.S. patent application Ser. No. 16/112,249, entitled SURGICAL        CLIP APPLIER COMPRISING AN AUTOMATIC CLIP FEEDING SYSTEM;    -   U.S. patent application Ser. No. 16/112,253, entitled SURGICAL        CLIP APPLIER COMPRISING ADAPTIVE FIRING CONTROL; and    -   U.S. patent application Ser. No. 16/112,257, entitled SURGICAL        CLIP APPLIER COMPRISING ADAPTIVE CONTROL IN RESPONSE TO A STRAIN        GAUGE CIRCUIT.

Applicant of the present application owns the following U.S. patentapplications that were filed on May 1, 2018 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. Provisional Patent Application Ser. No. 62/665,129,        entitled SURGICAL SUTURING SYSTEMS;    -   U.S. Provisional Patent Application Ser. No. 62/665,139,        entitled SURGICAL INSTRUMENTS COMPRISING CONTROL SYSTEMS;    -   U.S. Provisional Patent Application Ser. No. 62/665,177,        entitled SURGICAL INSTRUMENTS COMPRISING HANDLE ARRANGEMENTS;    -   U.S. Provisional Patent Application Ser. No. 62/665,128,        entitled MODULAR SURGICAL INSTRUMENTS;    -   U.S. Provisional Patent Application Ser. No. 62/665,192,        entitled SURGICAL DISSECTORS; and    -   U.S. Provisional Patent Application Ser. No. 62/665,134,        entitled SURGICAL CLIP APPLIER.

Applicant of the present application owns the following U.S. patentapplications that were filed on Feb. 28, 2018 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/908,021, entitled SURGICAL        INSTRUMENT WITH REMOTE RELEASE;    -   U.S. patent application Ser. No. 15/908,012, entitled SURGICAL        INSTRUMENT HAVING DUAL ROTATABLE MEMBERS TO EFFECT DIFFERENT        TYPES OF END EFFECTOR MOVEMENT;    -   U.S. patent application Ser. No. 15/908,040, entitled SURGICAL        INSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE END        EFFECTOR FUNCTIONS;    -   U.S. patent application Ser. No. 15/908,057, entitled SURGICAL        INSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE END        EFFECTOR FUNCTIONS;    -   U.S. patent application Ser. No. 15/908,058, entitled SURGICAL        INSTRUMENT WITH MODULAR POWER SOURCES; and    -   U.S. patent application Ser. No. 15/908,143, entitled SURGICAL        INSTRUMENT WITH SENSOR AND/OR CONTROL SYSTEMS.

Applicant of the present application owns the following U.S. patentapplications that were filed on Oct. 30, 2017 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. Provisional Patent Application Ser. No. 62/578,793,        entitled SURGICAL INSTRUMENT WITH REMOTE RELEASE;    -   U.S. Provisional Patent Application Ser. No. 62/578,804,        entitled SURGICAL INSTRUMENT HAVING DUAL ROTATABLE MEMBERS TO        EFFECT DIFFERENT TYPES OF END EFFECTOR MOVEMENT;    -   U.S. Provisional Patent Application Ser. No. 62/578,817,        entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY        ACTUATING MULTIPLE END EFFECTOR FUNCTIONS;    -   U.S. Provisional Patent Application Ser. No. 62/578,835,        entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY        ACTUATING MULTIPLE END EFFECTOR FUNCTIONS;    -   U.S. Provisional Patent Application Ser. No. 62/578,844,        entitled SURGICAL INSTRUMENT WITH MODULAR POWER SOURCES; and    -   U.S. Provisional Patent Application Ser. No. 62/578,855,        entitled SURGICAL INSTRUMENT WITH SENSOR AND/OR CONTROL SYSTEMS.

Applicant of the present application owns the following U.S. Provisionalpatent applications, filed on Dec. 28, 2017, the disclosure of each ofwhich is herein incorporated by reference in its entirety:

-   -   U.S. Provisional Patent Application Ser. No. 62/611,341,        entitled INTERACTIVE SURGICAL PLATFORM;    -   U.S. Provisional Patent Application Ser. No. 62/611,340,        entitled CLOUD-BASED MEDICAL ANALYTICS; and    -   U.S. Provisional Patent Application Ser. No. 62/611,339,        entitled ROBOT ASSISTED SURGICAL PLATFORM.

Applicant of the present application owns the following U.S. Provisionalpatent applications, filed on Mar. 28, 2018, each of which is hereinincorporated by reference in its entirety:

-   -   U.S. Provisional Patent Application Ser. No. 62/649,302,        entitled INTERACTIVE SURGICAL SYSTEMS WITH ENCRYPTED        COMMUNICATION CAPABILITIES;    -   U.S. Provisional Patent Application Ser. No. 62/649,294,        entitled DATA STRIPPING METHOD TO INTERROGATE PATIENT RECORDS        AND CREATE ANONYMIZED RECORD;    -   U.S. Provisional Patent Application Ser. No. 62/649,300,        entitled SURGICAL HUB SITUATIONAL AWARENESS;    -   U.S. Provisional Patent Application Ser. No. 62/649,309,        entitled SURGICAL HUB SPATIAL AWARENESS TO DETERMINE DEVICES IN        OPERATING THEATER;    -   U.S. Provisional Patent Application Ser. No. 62/649,310,        entitled COMPUTER IMPLEMENTED INTERACTIVE SURGICAL SYSTEMS;    -   U.S. Provisional Patent Application Ser. No. 62/649,291,        entitled USE OF LASER LIGHT AND RED-GREEN-BLUE COLORATION TO        DETERMINE PROPERTIES OF BACK SCATTERED LIGHT;    -   U.S. Provisional Patent Application Ser. No. 62/649,296,        entitled ADAPTIVE CONTROL PROGRAM UPDATES FOR SURGICAL DEVICES;    -   U.S. Provisional Patent Application Ser. No. 62/649,333,        entitled CLOUD-BASED MEDICAL ANALYTICS FOR CUSTOMIZATION AND        RECOMMENDATIONS TO A USER;    -   U.S. Provisional Patent Application Ser. No. 62/649,327,        entitled CLOUD-BASED MEDICAL ANALYTICS FOR SECURITY AND        AUTHENTICATION TRENDS AND REACTIVE MEASURES;    -   U.S. Provisional Patent Application Ser. No. 62/649,315,        entitled DATA HANDLING AND PRIORITIZATION IN A CLOUD ANALYTICS        NETWORK;    -   U.S. Provisional Patent Application Ser. No. 62/649,313,        entitled CLOUD INTERFACE FOR COUPLED SURGICAL DEVICES;    -   U.S. Provisional Patent Application Ser. No. 62/649,320,        entitled DRIVE ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL        PLATFORMS;    -   U.S. Provisional Patent Application Ser. No. 62/649,307,        entitled AUTOMATIC TOOL ADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL        PLATFORMS; and    -   U.S. Provisional Patent Application Ser. No. 62/649,323,        entitled SENSING ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL        PLATFORMS.

Applicant of the present application owns the following U.S. patentapplications, filed on Mar. 29, 2018, each of which is hereinincorporated by reference in its entirety:

-   -   U.S. patent application Ser. No. 15/940,641, entitled        INTERACTIVE SURGICAL SYSTEMS WITH ENCRYPTED COMMUNICATION        CAPABILITIES;    -   U.S. patent application Ser. No. 15/940,648, entitled        INTERACTIVE SURGICAL SYSTEMS WITH CONDITION HANDLING OF DEVICES        AND DATA CAPABILITIES;    -   U.S. patent application Ser. No. 15/940,656, entitled SURGICAL        HUB COORDINATION OF CONTROL AND COMMUNICATION OF OPERATING ROOM        DEVICES;    -   U.S. patent application Ser. No. 15/940,666, entitled SPATIAL        AWARENESS OF SURGICAL HUBS IN OPERATING ROOMS;    -   U.S. patent application Ser. No. 15/940,670, entitled        COOPERATIVE UTILIZATION OF DATA DERIVED FROM SECONDARY SOURCES        BY INTELLIGENT SURGICAL HUBS;    -   U.S. patent application Ser. No. 15/940,677, entitled SURGICAL        HUB CONTROL ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/940,632, entitled DATA        STRIPPING METHOD TO INTERROGATE PATIENT RECORDS AND CREATE        ANONYMIZED RECORD;    -   U.S. patent application Ser. No. 15/940,640, entitled        COMMUNICATION HUB AND STORAGE DEVICE FOR STORING PARAMETERS AND        STATUS OF A SURGICAL DEVICE TO BE SHARED WITH CLOUD BASED        ANALYTICS SYSTEMS;    -   U.S. patent application Ser. No. 15/940,645, entitled SELF        DESCRIBING DATA PACKETS GENERATED AT AN ISSUING INSTRUMENT;    -   U.S. patent application Ser. No. 15/940,649, entitled DATA        PAIRING TO INTERCONNECT A DEVICE MEASURED PARAMETER WITH AN        OUTCOME;    -   U.S. patent application Ser. No. 15/940,654, entitled SURGICAL        HUB SITUATIONAL AWARENESS;    -   U.S. patent application Ser. No. 15/940,663, entitled SURGICAL        SYSTEM DISTRIBUTED PROCESSING;    -   U.S. patent application Ser. No. 15/940,668, entitled        AGGREGATION AND REPORTING OF SURGICAL HUB DATA;    -   U.S. patent application Ser. No. 15/940,671, entitled SURGICAL        HUB SPATIAL AWARENESS TO DETERMINE DEVICES IN OPERATING THEATER;    -   U.S. patent application Ser. No. 15/940,686, entitled DISPLAY OF        ALIGNMENT OF STAPLE CARTRIDGE TO PRIOR LINEAR STAPLE LINE;    -   U.S. patent application Ser. No. 15/940,700, entitled STERILE        FIELD INTERACTIVE CONTROL DISPLAYS;    -   U.S. patent application Ser. No. 15/940,629, entitled COMPUTER        IMPLEMENTED INTERACTIVE SURGICAL SYSTEMS;    -   U.S. patent application Ser. No. 15/940,704, entitled USE OF        LASER LIGHT AND RED-GREEN-BLUE COLORATION TO DETERMINE        PROPERTIES OF BACK SCATTERED LIGHT;    -   U.S. patent application Ser. No. 15/940,722, entitled        CHARACTERIZATION OF TISSUE IRREGULARITIES THROUGH THE USE OF        MONO-CHROMATIC LIGHT REFRACTIVITY; and    -   U.S. patent application Ser. No. 15/940,742, entitled DUAL CMOS        ARRAY IMAGING.

Applicant of the present application owns the following U.S. patentapplications, filed on Mar. 29, 2018, each of which is hereinincorporated by reference in its entirety:

-   -   U.S. patent application Ser. No. 15/940,636, entitled ADAPTIVE        CONTROL PROGRAM UPDATES FOR SURGICAL DEVICES;    -   U.S. patent application Ser. No. 15/940,653, entitled ADAPTIVE        CONTROL PROGRAM UPDATES FOR SURGICAL HUBS;    -   U.S. patent application Ser. No. 15/940,660, entitled        CLOUD-BASED MEDICAL ANALYTICS FOR CUSTOMIZATION AND        RECOMMENDATIONS TO A USER;    -   U.S. patent application Ser. No. 15/940,679, entitled        CLOUD-BASED MEDICAL ANALYTICS FOR LINKING OF LOCAL USAGE TRENDS        WITH THE RESOURCE ACQUISITION BEHAVIORS OF LARGER DATA SET;    -   U.S. patent application Ser. No. 15/940,694, entitled        CLOUD-BASED MEDICAL ANALYTICS FOR MEDICAL FACILITY SEGMENTED        INDIVIDUALIZATION OF INSTRUMENT FUNCTION;    -   U.S. patent application Ser. No. 15/940,634, entitled        CLOUD-BASED MEDICAL ANALYTICS FOR SECURITY AND AUTHENTICATION        TRENDS AND REACTIVE MEASURES;    -   U.S. patent application Ser. No. 15/940,706, entitled DATA        HANDLING AND PRIORITIZATION IN A CLOUD ANALYTICS NETWORK; and    -   U.S. patent application Ser. No. 15/940,675, entitled CLOUD        INTERFACE FOR COUPLED SURGICAL DEVICES.

Applicant of the present application owns the following U.S. patentapplications, filed on Mar. 29, 2018, each of which is hereinincorporated by reference in its entirety:

-   -   U.S. patent application Ser. No. 15/940,627, entitled DRIVE        ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;    -   U.S. patent application Ser. No. 15/940,637, entitled        COMMUNICATION ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL        PLATFORMS;    -   U.S. patent application Ser. No. 15/940,642, entitled CONTROLS        FOR ROBOT-ASSISTED SURGICAL PLATFORMS;    -   U.S. patent application Ser. No. 15/940,676, entitled AUTOMATIC        TOOL ADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;    -   U.S. patent application Ser. No. 15/940,680, entitled        CONTROLLERS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;    -   U.S. patent application Ser. No. 15/940,683, entitled        COOPERATIVE SURGICAL ACTIONS FOR ROBOT-ASSISTED SURGICAL        PLATFORMS;    -   U.S. patent application Ser. No. 15/940,690, entitled DISPLAY        ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; and    -   U.S. patent application Ser. No. 15/940,711, entitled SENSING        ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS.

Applicant of the present application owns the following U.S. Provisionalpatent applications, filed on Mar. 30, 2018, each of which is hereinincorporated by reference in its entirety:

-   -   U.S. Provisional Patent Application Ser. No. 62/650,887,        entitled SURGICAL SYSTEMS WITH OPTIMIZED SENSING CAPABILITIES;    -   U.S. Provisional Patent Application Ser. No. 62/650,877,        entitled SURGICAL SMOKE EVACUATION SENSING AND CONTROLS;    -   U.S. Provisional Patent Application Ser. No. 62/650,882,        entitled SMOKE EVACUATION MODULE FOR INTERACTIVE SURGICAL        PLATFORM; and    -   U.S. Provisional Patent Application Ser. No. 62/650,898,        entitled CAPACITIVE COUPLED RETURN PATH PAD WITH SEPARABLE ARRAY        ELEMENTS.

Applicant of the present application owns the following U.S. Provisionalpatent application, filed on Apr. 19, 2018, which is herein incorporatedby reference in its entirety:

-   -   U.S. Provisional Patent Application Ser. No. 62/659,900,        entitled METHOD OF HUB COMMUNICATION.

Applicant of the present application owns the following U.S. Provisionalpatent applications, filed on Oct. 25, 2018, each of which is hereinincorporated by reference in its entirety:

-   -   U.S. Provisional Patent Application Ser. No. 62/750,529,        entitled METHOD FOR OPERATING A POWERED ARTICULATING MULTI-CLIP        APPLIER;    -   U.S. Provisional Patent Application Ser. No. 62/750,539,        entitled SURGICAL CLIP APPLIER; and    -   U.S. Provisional Patent Application Ser. No. 62/750,555,        entitled SURGICAL CLIP APPLIER.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”), and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes”, or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes”, or “contains” one or more features possesses thoseone or more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical instrument, such as a grasper, for example, can comprise ahandle, a shaft extending from the handle, and an end effector extendingfrom the shaft. In various instances, the end effector comprises a firstjaw and a second jaw, wherein one or both of the jaws are movablerelative to the other to grasp the tissue of a patient. That said, anend effector of a surgical instrument can comprise any suitablearrangement and can perform any suitable function. For instance, an endeffector can comprise first and second jaws configured to dissect orseparate the tissue of a patient. Also, for instance, an end effectorcan be configured to suture and/or clip the tissue of a patient. Invarious instances, the end effector and/or shaft of the surgicalinstrument are configured to be inserted into a patient through atrocar, or cannula, and can have any suitable diameter, such asapproximately 5 mm, 8 mm, and/or 12 mm, for example. U.S. patentapplication Ser. No. 11/013,924, entitled TROCAR SEAL ASSEMBLY, now U.S.Pat. No. 7,371,227, is incorporated by reference in its entirety. Theshaft can define a longitudinal axis and at least a portion of the endeffector can be rotatable about the longitudinal axis. Moreover, thesurgical instrument can further comprise an articulation joint which canpermit at least a portion of the end effector to be articulated relativeto the shaft. In use, a clinician can rotate and/or articulate the endeffector in order to maneuver the end effector within the patient.

A surgical instrument system is depicted in FIG. 1. The surgicalinstrument system comprises a handle assembly 1000 which is selectivelyusable with a shaft assembly 2000, a shaft assembly 3000, a shaftassembly 4000, a shaft assembly 5000, and/or any other suitable shaftassembly. The shaft assembly 2000 is attached to the handle assembly1000 in FIG. 2 and the shaft assembly 4000 is attached to the handleassembly 1000 in FIG. 45. The shaft assembly 2000 comprises a proximalportion 2100, an elongate shaft 2200 extending from the proximal portion2100, a distal attachment portion 2400, and an articulation joint 2300rotatably connecting the distal attachment portion 2400 to the elongateshaft 2200. The shaft assembly 2000 further comprises a replaceable endeffector assembly 7000 attached to the distal attachment portion 2400.The replaceable end effector assembly 7000 comprises a jaw assembly 7100configured to be opened and closed to clamp and/or manipulate the tissueof a patient. In use, the end effector assembly 7000 can be articulatedabout the articulation joint 2300 and/or rotated relative to the distalattachment portion 2400 about a longitudinal axis to better position thejaw assembly 7100 within the patient, as described in greater detailfurther below.

Referring again to FIG. 1, the handle assembly 1000 comprises, amongother things, a drive module 1100. As described in greater detail below,the drive module 1100 comprises a distal mounting interface whichpermits a clinician to selectively attach one of the shaft assemblies2000, 3000, 4000, and 5000, for example, to the drive module 1100. Thus,each of the shaft assemblies 2000, 3000, 4000, and 5000 comprises anidentical, or an at least similar, proximal mounting interface which isconfigured to engage the distal mounting interface of the drive module1100. As also described in greater detail below, the mounting interfaceof the drive module 1100 mechanically secures and electrically couplesthe selected shaft assembly to the drive module 1100. The drive module1100 further comprises at least one electric motor, one or more controlsand/or displays, and a controller configured to operate the electricmotor—the rotational output of which is transmitted to a drive system ofthe shaft assembly attached to the drive module 1100. Moreover, thedrive module 1100 is usable with one ore more power modules, such aspower modules 1200 and 1300, for example, which are operably attachableto the drive module 1100 to supply power thereto.

Further to the above, referring again to FIGS. 1 and 2, the handle drivemodule 1100 comprises a housing 1110, a first module connector 1120, anda second module connector 1120′. The power module 1200 comprises ahousing 1210, a connector 1220, one or more release latches 1250, andone or more batteries 1230. The connector 1220 is configured to beengaged with the first module connector 1120 of the drive module 1100 inorder to attach the power module 1200 to the drive module 1100. Theconnector 1220 comprises one or more latches 1240 which mechanicallycouple and fixedly secure the housing 1210 of the power module 1200 tothe housing 1110 of the drive module 1100. The latches 1240 are movableinto disengaged positions when the release latches 1250 are depressed sothat the power module 1200 can be detached from the drive module 1100.The connector 1220 also comprises one or more electrical contacts whichplace the batteries 1230, and/or an electrical circuit including thebatteries 1230, in electrical communication with an electrical circuitin the drive module 1100.

Further to the above, referring again to FIGS. 1 and 2, the power module1300 comprises a housing 1310, a connector 1320, one or more releaselatches 1350, and one or more batteries 1330 (FIG. 47). The connector1320 is configured to be engaged with the second module connector 1120′of the drive module 1100 to attach the power module 1300 to the drivemodule 1100. The connector 1320 comprises one or more latches 1340 whichmechanically couple and fixedly secure the housing 1310 of the powermodule 1300 to the housing 1110 of the drive module 1100. The latches1340 are movable into disengaged positions when the release latches 1350are depressed so that the power module 1300 can be detached from thedrive module 1100. The connector 1320 also comprises one or moreelectrical contacts which place the batteries 1330 of the power module1300, and/or an electrical power circuit including the batteries 1330,in electrical communication with an electrical power circuit in thedrive module 1100.

Further to the above, the power module 1200, when attached to the drivemodule 1100, comprises a pistol grip which can allow a clinician to holdthe handle 1000 in a manner which places the drive module 1100 on top ofthe clinician's hand. The power module 1300, when attached to the drivemodule 1100, comprises an end grip which allows a clinician to hold thehandle 1000 like a wand. The power module 1200 is longer than the powermodule 1300, although the power modules 1200 and 1300 can comprise anysuitable length. The power module 1200 has more battery cells than thepower module 1300 and can suitably accommodate these additional batterycells owing to its length. In various instances, the power module 1200can provide more power to the drive module 1100 than the power module1300 while, in some instances, the power module 1200 can provide powerfor a longer period of time. In some instances, the housing 1110 of thedrive module 1100 comprises keys, and/or any other suitable features,which prevent the power module 1200 from being connected to the secondmodule connector 1120′ and, similarly, prevent the power module 1300from being connected to the first module connector 1120. Such anarrangement can assure that the longer power module 1200 is used in thepistol grip arrangement and that the shorter power module 1300 is usedin the wand grip arrangement. In alternative embodiments, the powermodule 1200 and the power module 1300 can be selectively coupled to thedrive module 1100 at either the first module connector 1120 or thesecond module connector 1120′. Such embodiments provide a clinician withmore options to customize the handle 1000 in a manner suitable to them.

In various instances, further to the above, only one of the powermodules 1200 and 1300 is coupled to the drive module 1100 at a time. Incertain instances, the power module 1200 can be in the way when theshaft assembly 4000, for example, is attached to the drive module 1100.Alternatively, both of the power modules 1200 and 1300 can be operablycoupled to the drive module 1100 at the same time. In such instances,the drive module 1100 can have access to power provided by both of thepower modules 1200 and 1300. Moreover, a clinician can switch between apistol grip and a wand grip when both of the power modules 1200 and 1300are attached to the drive module 1100. Moreover, such an arrangementallows the power module 1300 to act as a counterbalance to a shaftassembly, such as shaft assemblies 2000, 3000, 4000, or 5000, forexample, attached to the drive module 1100.

Referring to FIGS. 7 and 8, the handle drive module 1100 furthercomprises a frame 1500, a motor assembly 1600, a drive system 1700operably engaged with the motor assembly 1600, and a control system1800. The frame 1500 comprises an elongate shaft that extends throughthe motor assembly 1600. The elongate shaft comprises a distal end 1510and electrical contacts, or sockets, 1520 defined in the distal end1510. The electrical contacts 1520 are in electrical communication withthe control system 1800 of the drive module 1100 via one or moreelectrical circuits and are configured to convey signals and/or powerbetween the control system 1800 and the shaft assembly, such as theshaft assembly 2000, 3000, 4000, or 5000, for example, attached to thedrive module 1100. The control system 1800 comprises a printed circuitboard (PCB) 1810, at least one microprocessor 1820, and at least onememory device 1830. The board 1810 can be rigid and/or flexible and cancomprise any suitable number of layers. The microprocessor 1820 and thememory device 1830 are part of a control circuit defined on the board1810 which controls the operation of the motor assembly 1600, asdescribed in greater detail below.

Referring to FIGS. 12 and 13, the motor assembly 1600 comprises anelectric motor 1610 including a housing 1620, a drive shaft 1630, and agear reduction system. The electric motor 1610 further comprises astator including windings 1640 and a rotor including magnetic elements1650. The stator windings 1640 are supported in the housing 1620 and therotor magnetic elements 1650 are mounted to the drive shaft 1630. Whenthe stator windings 1640 are energized with an electric currentcontrolled by the control system 1800, the drive shaft 1630 is rotatedabout a longitudinal axis. The drive shaft 1630 is operably engaged witha first planetary gear system 1660 which includes a central sun gear andseveral planetary gears operably intermeshed with the sun gear. The sungear of the first planetary gear system 1660 is fixedly mounted to thedrive shaft 1630 such that it rotates with the drive shaft 1630. Theplanetary gears of the first planetary gear system 1660 are rotatablymounted to the sun gear of a second planetary gear system 1670 and,also, intermeshed with a geared or splined inner surface 1625 of themotor housing 1620. As a result of the above, the rotation of the firstsun gear rotates the first planetary gears which rotate the second sungear. Similar to the above, the second planetary gear system 1670further comprises planetary gears 1665 (FIG. 13) which drive a thirdplanetary gear system and, ultimately, the drive shaft 1710. Theplanetary gear systems 1660, 1670, and 1680 co-operate to gear down thespeed applied to the drive shaft 1710 by the motor shaft 1620. Variousalternative embodiments are envisioned without a speed reduction system.Such embodiments are suitable when it is desirable to drive the endeffector functions quickly. Notably, the drive shaft 1630 comprises anaperture, or hollow core, extending therethrough through which wiresand/or electrical circuits can extend.

The control system 1800 is in communication with the motor assembly 1600and the electrical power circuit of the drive module 1100. The controlsystem 1800 is configured to control the power delivered to the motorassembly 1600 from the electrical power circuit. The electrical powercircuit is configured to supply a constant, or at least nearly constant,direct current (DC) voltage. In at least one instance, the electricalpower circuit supplies 3 VDC to the control system 1800. The controlsystem 1800 comprises a pulse width modulation (PWM) circuit which isconfigured to deliver voltage pulses to the motor assembly 1600. Theduration or width of the voltage pulses, and/or the duration or widthbetween the voltage pulses, supplied by the PWM circuit can becontrolled in order to control the power applied to the motor assembly1600. By controlling the power applied to the motor assembly 1600, thePWM circuit can control the speed of the output shaft of the motorassembly 1600. In addition to or in lieu of a PWM circuit, the controlsystem 1800 can include a frequency modulation (FM) circuit. Asdiscussed in greater detail below, the control system 1800 is operablein more than one operating mode and, depending on the operating modebeing used, the control system 1800 can operate the motor assembly 1600at a speed, or a range of speeds, which is determined to be appropriatefor that operating mode.

Further to the above, referring again to FIGS. 7 and 8, the drive system1700 comprises a rotatable shaft 1710 comprising a splined distal end1720 and a longitudinal aperture 1730 defined therein. The rotatableshaft 1710 is operably mounted to the output shaft of the motor assembly1600 such that the rotatable shaft 1710 rotates with the motor outputshaft. The handle frame 1510 extends through the longitudinal aperture1730 and rotatably supports the rotatable shaft 1710. As a result, thehandle frame 1510 serves as a bearing for the rotatable shaft 1710. Thehandle frame 1510 and the rotatable shaft 1710 extend distally from amounting interface 1130 of the drive module 1110 and are coupled withcorresponding components on the shaft assembly 2000 when the shaftassembly 2000 is assembled to the drive module 1100. Referring primarilyto FIGS. 3-6, the shaft assembly 2000 further comprises a frame 2500 anda drive system 2700. The frame 2500 comprises a longitudinal shaft 2510extending through the shaft assembly 2000 and a plurality of electricalcontacts, or pins, 2520 extending proximally from the shaft 2510. Whenthe shaft assembly 2000 is attached to the drive module 1100, theelectrical contacts 2520 on the shaft frame 2510 engage the electricalcontacts 1520 on the handle frame 1510 and create electrical pathwaystherebetween.

Similar to the above, the drive system 2700 comprises a rotatable driveshaft 2710 which is operably coupled to the rotatable drive shaft 1710of the handle 1000 when the shaft assembly 2000 is assembled to thedrive module 1100 such that the drive shaft 2710 rotates with the driveshaft 1710. To this end, the drive shaft 2710 comprises a splinedproximal end 2720 which mates with the splined distal end 1720 of thedrive shaft 1710 such that the drive shafts 1710 and 2710 rotatetogether when the drive shaft 1710 is rotated by the motor assembly1600. Given the nature of the splined interconnection between the driveshafts 1710 and 2710 and the electrical interconnection between theframes 1510 and 2510, the shaft assembly 2000 is assembled to the handle1000 along a longitudinal axis; however, the operable interconnectionbetween the drive shafts 1710 and 2710 and the electricalinterconnection between the frames 1510 and 2510 can comprise anysuitable configuration which can allow a shaft assembly to be assembledto the handle 1000 in any suitable manner.

As discussed above, referring to FIGS. 3-8, the mounting interface 1130of the drive module 1110 is configured to be coupled to a correspondingmounting interface on the shaft assemblies 2000, 3000, 4000, and 5000,for example. For instance, the shaft assembly 2000 comprises a mountinginterface 2130 configured to be coupled to the mounting interface 1130of the drive module 1100. More specifically, the proximal portion 2100of the shaft assembly 2000 comprises a housing 2110 which defines themounting interface 2130. Referring primarily to FIG. 8, the drive module1100 comprises latches 1140 which are configured to releasably hold themounting interface 2130 of the shaft assembly 2000 against the mountinginterface 1130 of the drive module 1100. When the drive module 1100 andthe shaft assembly 2000 are brought together along a longitudinal axis,as described above, the latches 1140 contact the mounting interface 2130and rotate outwardly into an unlocked position. Referring primarily toFIGS. 8, 10, and 11, each latch 1140 comprises a lock end 1142 and apivot portion 1144. The pivot portion 1144 of each latch 1140 isrotatably coupled to the housing 1110 of the drive module 1100 and, whenthe latches 1140 are rotated outwardly, as mentioned above, the latches1140 rotate about the pivot portions 1144. Notably, each latch 1140further comprises a biasing spring 1146 configured to bias the latches1140 inwardly into a locked position. Each biasing spring 1146 iscompressed between a latch 1140 and the housing 1110 of the drive module1100 such that the biasing springs 1146 apply biasing forces to thelatches 1140; however, such biasing forces are overcome when the latches1140 are rotated outwardly into their unlocked positions by the shaftassembly 2000. That said, when the latches 1140 rotate outwardly aftercontacting the mounting interface 2130, the lock ends 1142 of thelatches 1140 can enter into latch windows 2140 defined in the mountinginterface 2130. Once the lock ends 1142 pass through the latch windows2140, the springs 1146 can bias the latches 1140 back into their lockedpositions. Each lock end 1142 comprises a lock shoulder, or surface,which securely holds the shaft assembly 2000 to the drive module 1100.

Further to the above, the biasing springs 1146 hold the latches 1140 intheir locked positions. The distal ends 1142 are sized and configured toprevent, or at least inhibit, relative longitudinal movement, i.e.,translation along a longitudinal axis, between the shaft assembly 2000and the drive module 1100 when the latches 1140 are in their lockedpositions. Moreover, the latches 1140 and the latch windows 1240 aresized and configured to prevent relative lateral movement, i.e.,translation transverse to the longitudinal axis, between the shaftassembly 2000 and the drive module 1100. In addition, the latches 1140and the latch windows 2140 are sized and configured to prevent the shaftassembly 2000 from rotating relative to the drive module 1100. The drivemodule 1100 further comprises release actuators 1150 which, whendepressed by a clinician, move the latches 1140 from their lockedpositions into their unlocked positions. The drive module 1100 comprisesa first release actuator 1150 slideably mounted in an opening defined inthe first side of the handle housing 1110 and a second release actuator1150 slideably mounted in an opening defined in a second, or opposite,side of the handle housing 1110. Although the release actuators 1150 areactuatable separately, both release actuators 1150 typically need to bedepressed to completely unlock the shaft assembly 2000 from the drivemodule 1100 and allow the shaft assembly 2000 to be detached from thedrive module 1100. That said, it is possible that the shaft assembly2000 could be detached from the drive module 1100 by depressing only onerelease actuator 1150.

Once the shaft assembly 2000 has been secured to the handle 1000 and theend effector 7000, for example, has been assembled to the shaft 2000,the clinician can maneuver the handle 1000 to insert the end effector7000 into a patient. In at least one instance, the end effector 7000 isinserted into the patient through a trocar and then manipulated in orderto position the jaw assembly 7100 of the end effector assembly 7000relative to the patient's tissue. Oftentimes, the jaw assembly 7100 mustbe in its closed, or clamped, configuration in order to fit through thetrocar. Once through the trocar, the jaw assembly 7100 can be opened sothat the patient tissue fit between the jaws of the jaw assembly 7100.At such point, the jaw assembly 7100 can be returned to its closedconfiguration to clamp the patient tissue between the jaws. The clampingforce applied to the patient tissue by the jaw assembly 7100 issufficient to move or otherwise manipulate the tissue during a surgicalprocedure. Thereafter, the jaw assembly 7100 can be re-opened to releasethe patient tissue from the end effector 7000. This process can berepeated until it is desirable to remove the end effector 7000 from thepatient. At such point, the jaw assembly 7100 can be returned to itsclosed configuration and retracted through the trocar. Other surgicaltechniques are envisioned in which the end effector 7000 is insertedinto a patient through an open incision, or without the use of thetrocar. In any event, it is envisioned that the jaw assembly 7100 mayhave to be opened and closed several times throughout a surgicaltechnique.

Referring again to FIGS. 3-6, the shaft assembly 2000 further comprisesa clamping trigger system 2600 and a control system 2800. The clampingtrigger system 2600 comprises a clamping trigger 2610 rotatablyconnected to the proximal housing 2110 of the shaft assembly 2000. Asdiscussed below, the clamping trigger 2610 actuates the motor 1610 tooperate the jaw drive of the end effector 7000 when the clamping trigger2610 is actuated. The clamping trigger 2610 comprises an elongateportion which is graspable by the clinician while holding the handle1000. The clamping trigger 2610 further comprises a mounting portion2620 which is pivotably connected to a mounting portion 2120 of theproximal housing 2110 such that the clamping trigger 2610 is rotatableabout a fixed, or an at least substantially fixed, axis. The closuretrigger 2610 is rotatable between a distal position and a proximalposition, wherein the proximal position of the closure trigger 2610 iscloser to the pistol grip of the handle 1000 than the distal position.The closure trigger 2610 further comprises a tab 2615 extendingtherefrom which rotates within the proximal housing 2110. When theclosure trigger 2610 is in its distal position, the tab 2615 ispositioned above, but not in contact with, a switch 2115 mounted on theproximal housing 2110. The switch 2115 is part of an electrical circuitconfigured to detect the actuation of the closure trigger 2610 which isin an open condition the closure trigger 2610 is in its open position.When the closure trigger 2610 is moved into its proximal position, thetab 2615 comes into contact with the switch 2115 and closes theelectrical circuit. In various instances, the switch 2115 can comprise atoggle switch, for example, which is mechanically switched between openand closed states when contacted by the tab 2615 of the closure trigger2610. In certain instances, the switch 2115 can comprise a proximitysensor, for example, and/or any suitable type of sensor. In at least oneinstance, the switch 2115 comprises a Hall Effect sensor which candetect the amount in which the closure trigger 2610 has been rotatedand, based on the amount of rotation, control the speed in which themotor 1610 is operated. In such instances, larger rotations of theclosure trigger 2610 result in faster speeds of the motor 1610 whilesmaller rotations result in slower speeds, for example. In any event,the electrical circuit is in communication with the control system 2800of the shaft assembly 2000, which is discussed in greater detail below.

Further to the above, the control system 2800 of the shaft assembly 2000comprises a printed circuit board (PCB) 2810, at least onemicroprocessor 2820, and at least one memory device 2830. The board 2810can be rigid and/or flexible and can comprise any suitable number oflayers. The microprocessor 2820 and the memory device 2830 are part of acontrol circuit defined on the board 2810 which communicates with thecontrol system 1800 of the handle 1000. The shaft assembly 2000 furthercomprises a signal communication system 2900 and the handle 1000 furthercomprises a signal communication system 1900 which are configured toconvey data between the shaft control system 2800 and the handle controlsystem 1800. The signal communication system 2900 is configured totransmit data to the signal communication system 1900 utilizing anysuitable analog and/or digital components. In various instances, thecommunication systems 2900 and 1900 can communicate using a plurality ofdiscrete channels which allows the input gates of the microprocessor1820 to be directly controlled, at least in part, by the output gates ofthe microprocessor 2820. In some instances, the communication systems2900 and 1900 can utilize multiplexing. In at least one such instance,the control system 2900 includes a multiplexing device that sendsmultiple signals on a carrier channel at the same time in the form of asingle, complex signal to a multiplexing device of the control system1900 that recovers the separate signals from the complex signal.

The communication system 2900 comprises an electrical connector 2910mounted to the circuit board 2810. The electrical connector 2910comprises a connector body and a plurality of electrically-conductivecontacts mounted to the connector body. The electrically-conductivecontacts comprise male pins, for example, which are soldered toelectrical traces defined in the circuit board 2810. In other instances,the male pins can be in communication with circuit board traces throughzero-insertion-force (ZIF) sockets, for example. The communicationsystem 1900 comprises an electrical connector 1910 mounted to thecircuit board 1810. The electrical connector 1910 comprises a connectorbody and a plurality of electrically-conductive contacts mounted to theconnector body. The electrically-conductive contacts comprise femalepins, for example, which are soldered to electrical traces defined inthe circuit board 1810. In other instances, the female pins can be incommunication with circuit board traces through zero-insertion-force(ZIF) sockets, for example. When the shaft assembly 2000 is assembled tothe drive module 1100, the electrical connector 2910 is operably coupledto the electrical connector 1910 such that the electrical contacts formelectrical pathways therebetween. The above being said, the connectors1910 and 2910 can comprise any suitable electrical contacts. Moreover,the communication systems 1900 and 2900 can communicate with one anotherin any suitable manner. In various instances, the communication systems1900 and 2900 communicate wirelessly. In at least one such instance, thecommunication system 2900 comprises a wireless signal transmitter andthe communication system 1900 comprises a wireless signal receiver suchthat the shaft assembly 2000 can wirelessly communicate data to thehandle 1000. Likewise, the communication system 1900 can comprise awireless signal transmitter and the communication system 2900 cancomprise a wireless signal receiver such that the handle 1000 canwirelessly communicate data to the shaft assembly 2000.

As discussed above, the control system 1800 of the handle 1000 is incommunication with, and is configured to control, the electrical powercircuit of the handle 1000. The handle control system 1800 is alsopowered by the electrical power circuit of the handle 1000. The handlecommunication system 1900 is in signal communication with the handlecontrol system 1800 and is also powered by the electrical power circuitof the handle 1000. The handle communication system 1900 is powered bythe handle electrical power circuit via the handle control system 1800,but could be directly powered by the electrical power circuit. As alsodiscussed above, the handle communication system 1900 is in signalcommunication with the shaft communication system 2900. That said, theshaft communication system 2900 is also powered by the handle electricalpower circuit via the handle communication system 1900. To this end, theelectrical connectors 1910 and 2010 connect both one or more signalcircuits and one or more power circuits between the handle 1000 and theshaft assembly 2000. Moreover, the shaft communication system 2900 is insignal communication with the shaft control system 2800, as discussedabove, and is also configured to supply power to the shaft controlsystem 2800. Thus, the control systems 1800 and 2800 and thecommunication systems 1900 and 2900 are all powered by the electricalpower circuit of the handle 1000; however, alternative embodiments areenvisioned in which the shaft assembly 2000 comprises its own powersource, such as one or more batteries, for example, an and electricalpower circuit configured to supply power from the batteries to thehandle systems 2800 and 2900. In at least one such embodiment, thehandle control system 1800 and the handle communication system 1900 arepowered by the handle electrical power system and the shaft controlsystem 2800 and the handle communication system 2900 are powered by theshaft electrical power system.

Further to the above, the actuation of the clamping trigger 2610 isdetected by the shaft control system 2800 and communicated to the handlecontrol system 1800 via the communication systems 2900 and 1900. Uponreceiving a signal that the clamping trigger 2610 has been actuated, thehandle control system 1800 supplies power to the electric motor 1610 ofthe motor assembly 1600 to rotate the drive shaft 1710 of the handledrive system 1700, and the drive shaft 2710 of the shaft drive system2700, in a direction which closes the jaw assembly 7100 of the endeffector 7000. The mechanism for converting the rotation of the driveshaft 2710 to a closure motion of the jaw assembly 7100 is discussed ingreater detail below. So long as the clamping trigger 2610 is held inits actuated position, the electric motor 1610 will rotate the driveshaft 1710 until the jaw assembly 7100 reaches its fully-clampedposition. When the jaw assembly 7100 reaches its fully-clamped position,the handle control system 1800 cuts the electrical power to the electricmotor 1610. The handle control system 1800 can determine when the jawassembly 7100 has reached its fully-clamped position in any suitablemanner. For instance, the handle control system 1800 can comprise anencoder system which monitors the rotation of, and counts the rotationsof, the output shaft of the electric motor 1610 and, once the number ofrotations reaches a predetermined threshold, the handle control system1800 can discontinue supplying power to the electric motor 1610. In atleast one instance, the end effector assembly 7000 can comprise one ormore sensors configured to detect when the jaw assembly 7100 has reachedits fully-clamped position. In at least one such instance, the sensorsin the end effector 7000 are in signal communication with the handlecontrol system 1800 via electrical circuits extending through the shaftassembly 2000 which can include the electrical contacts 1520 and 2520,for example.

When the clamping trigger 2610 is rotated distally out of its proximalposition, the switch 2115 is opened which is detected by the shaftcontrol system 2800 and communicated to the handle control system 1800via the communication systems 2900 and 1900. Upon receiving a signalthat the clamping trigger 2610 has been moved out of its actuatedposition, the handle control system 1800 reverses the polarity of thevoltage differential being applied to the electric motor 1610 of themotor assembly 1600 to rotate the drive shaft 1710 of the handle drivesystem 1700, and the drive shaft 2710 of the shaft drive system 2700, inan opposite direction which, as a result, opens the jaw assembly 7100 ofthe end effector 7000. When the jaw assembly 7100 reaches its fully-openposition, the handle control system 1800 cuts the electrical power tothe electric motor 1610. The handle control system 1800 can determinewhen the jaw assembly 7100 has reached its fully-open position in anysuitable manner. For instance, the handle control system 1800 canutilize the encoder system and/or the one or more sensors describedabove to determine the configuration of the jaw assembly 7100. In viewof the above, the clinician needs to be mindful about holding theclamping trigger 2610 in its actuated position in order to maintain thejaw assembly 7100 in its clamped configuration as, otherwise, thecontrol system 1800 will open jaw assembly 7100. With this in mind, theshaft assembly 2000 further comprises an actuator latch 2630 configuredto releasably hold the clamping trigger 2610 in its actuated position toprevent the accidental opening of the jaw assembly 7100. The actuatorlatch 2630 can be manually released, or otherwise defeated, by theclinician to allow the clamping trigger 2610 to be rotated distally andopen the jaw assembly 7100.

The clamping trigger system 2600 further comprises a resilient biasingmember, such as a torsion spring, for example, configured to resist theclosure of the clamping trigger system 2600. The torsion spring can alsoassist in reducing and/or mitigating sudden movements and/or jitter ofthe clamping trigger 2610. Such a torsion spring can also automaticallyreturn the clamping trigger 2610 to its unactuated position when theclamping trigger 2610 is released. The actuator latch 2630 discussedabove can suitably hold the clamping trigger 2610 in its actuatedposition against the biasing force of the torsion spring.

As discussed above, the control system 1800 operates the electric motor1610 to open and close the jaw assembly 7100. The control system 1800 isconfigured to open and close the jaw assembly 7100 at the same speed. Insuch instances, the control system 1800 applies the same voltage pulsesto the electric motor 1610, albeit with different voltage polarities,when opening and closing the jaw assembly 7100. That said, the controlsystem 1800 can be configured to open and close the jaw assembly 7100 atdifferent speeds. For instance, the jaw assembly 7100 can be closed at afirst speed and opened at a second speed which is faster than the firstspeed. In such instances, the slower closing speed affords the clinicianan opportunity to better position the jaw assembly 7100 while clampingthe tissue. Alternatively, the control system 1800 can open the jawassembly 7100 at a slower speed. In such instances, the slower openingspeed reduces the possibility of the opening jaws colliding withadjacent tissue. In either event, the control system 1800 can decreasethe duration of the voltage pulses and/or increase the duration betweenthe voltage pulses to slow down and/or speed up the movement of the jawassembly 7100.

As discussed above, the control system 1800 is configured to interpretthe position of the clamping trigger 2610 as a command to position thejaw assembly 7100 in a specific configuration. For instance, the controlsystem 1800 is configured to interpret the proximal-most position of theclamping trigger 2610 as a command to close the jaw assembly 7100 andany other position of the clamping trigger as a command to open the jawassembly 7100. That said, the control system 1800 can be configured tointerpret the position of the clamping trigger 2610 in a proximal rangeof positions, instead of a single position, as a command to close thejaw assembly 7100. Such an arrangement can allow the jaw assembly 7000to be better responsive to the clinician's input. In such instances, therange of motion of the clamping trigger 2610 is divided into ranges—aproximal range which is interpreted as a command to close the jawassembly 7100 and a distal range which is interpreted as a command toopen the jaw assembly 7100. In at least one instance, the range ofmotion of the clamping trigger 2610 can have an intermediate rangebetween the proximal range and the distal range. When the clampingtrigger 2610 is in the intermediate range, the control system 1800 caninterpret the position of the clamping trigger 2610 as a command toneither open nor close the jaw assembly 7100. Such an intermediate rangecan prevent, or reduce the possibility of, jitter between the openingand closing ranges. In the instances described above, the control system1800 can be configured to ignore cumulative commands to open or closethe jaw assembly 7100. For instance, if the closure trigger 2610 hasalready been fully retracted into its proximal-most position, thecontrol assembly 1800 can ignore the motion of the clamping trigger 2610in the proximal, or clamping, range until the clamping trigger 2610enters into the distal, or opening, range wherein, at such point, thecontrol system 1800 can then actuate the electric motor 1610 to open thejaw assembly 7100.

In certain instances, further to the above, the position of the clampingtrigger 2610 within the clamping trigger range, or at least a portion ofthe clamping trigger range, can allow the clinician to control the speedof the electric motor 1610 and, thus, the speed in which the jawassembly 7100 is being opened or closed by the control assembly 1800. Inat least one instance, the sensor 2115 comprises a Hall Effect sensor,and/or any other suitable sensor, configured to detect the position ofthe clamping trigger 2610 between its distal, unactuated position andits proximal, fully-actuated position. The Hall Effect sensor isconfigured to transmit a signal to the handle control system 1800 viathe shaft control system 2800 such that the handle control system 1800can control the speed of the electric motor 1610 in response to theposition of the clamping trigger 2610. In at least one instance, thehandle control system 1800 controls the speed of the electric motor 1610proportionately, or in a linear manner, to the position of the clampingtrigger 2610. For example, if the clamping trigger 2610 is moved halfway through its range, then the handle control system 1800 will operatethe electric motor 1610 at half of the speed in which the electric motor1610 is operated when the clamping trigger 2610 is fully-retracted.Similarly, if the clamping trigger 2610 is moved a quarter way throughits range, then the handle control system 1800 will operate the electricmotor 1610 at a quarter of the speed in which the electric motor 1610 isoperated when the clamping trigger 2610 is fully-retracted. Otherembodiments are envisioned in which the handle control system 1800controls the speed of the electric motor 1610 in a non-linear manner tothe position of the clamping trigger 2610. In at least one instance, thecontrol system 1800 operates the electric motor 1610 slowly in thedistal portion of the clamping trigger range while quickly acceleratingthe speed of the electric motor 1610 in the proximal portion of theclamping trigger range.

As described above, the clamping trigger 2610 is movable to operate theelectric motor 1610 to open or close the jaw assembly 7100 of the endeffector 7000. The electric motor 1610 is also operable to rotate theend effector 7000 about a longitudinal axis and articulate the endeffector 7000 relative to the elongate shaft 2200 about the articulationjoint 2300 of the shaft assembly 2000. Referring primarily to FIGS. 7and 8, the drive module 1100 comprises an input system 1400 including arotation actuator 1420 and an articulation actuator 1430. The inputsystem 1400 further comprises a printed circuit board (PCB) 1410 whichis in signal communication with the printed circuit board (PCB) 1810 ofthe control system 1800. The drive module 1100 comprises an electricalcircuit, such as a flexible wiring harness or ribbon, for example, whichpermits the input system 1400 to communicate with the control system1800. The rotation actuator 1420 is rotatably supported on the housing1110 and is in signal communication with the input board 1410 and/orcontrol board 1810, as described in greater detail below. Thearticulation actuator 1430 is supported by and in signal communicationwith the input board 1410 and/or control board 1810, as also describedin greater detail below.

Referring primarily to FIGS. 8, 10, and 11, further to the above, thehandle housing 1110 comprises an annular groove or slot defined thereinadjacent the distal mounting interface 1130. The rotation actuator 1420comprises an annular ring 1422 rotatably supported within the annulargroove and, owing to the configuration of the sidewalls of the annulargroove, the annular ring 1422 is constrained from translatinglongitudinally and/or laterally with respect to the handle housing 1110.The annular ring 1422 is rotatable in a first, or clockwise, directionand a second, or counter-clockwise direction, about a longitudinal axisextending through the frame 1500 of the drive module 1100. The rotationactuator 1420 comprises one or more sensors configured to detect therotation of the annular ring 1422. In at least one instance, therotation actuator 1420 comprises a first sensor positioned on a firstside of the drive module 1100 and a second sensor positioned on asecond, or opposite, side of the drive module 1100 and the annular ring1422 comprises a detectable element which is detectable by the first andsecond sensors. The first sensor is configured to detect when theannular ring 1422 is rotated in the first direction and the secondsensor is configured to detect when the annular ring 1422 is rotated inthe second direction. When the first sensor detects that the annularring 1422 is rotated in the first direction, the handle control system1800 rotates the handle drive shaft 1710, the drive shaft 2710, and theend effector 7000 in the first direction, as described in greater detailbelow. Similarly, the handle control system 1800 rotates the handledrive shaft 1710, the drive shaft 2710, and the end effector 7000 in thesecond direction when the second sensor detects that the annular ring1422 is rotated in the second direction. In view of the above, thereader should appreciate that the clamping trigger 2610 and the rotationactuator 1420 are both operable to rotate the drive shaft 2710.

In various embodiments, further to the above, the first and secondsensors comprise switches which are mechanically closable by thedetectable element of the annular ring 1422. When the annular ring 1422is rotated in the first direction from a center position, the detectableelement closes the switch of the first sensor. When the switch of thefirst sensor is closed, the control system 1800 operates the electricmotor 1610 to rotate the end effector 7000 in the first direction. Whenthe annular ring 1422 is rotated in the second direction toward thecenter position, the detectable element is disengaged from the firstswitch and the first switch is re-opened. Once the first switch isre-opened, the control system 1800 cuts the power to the electric motor1610 to stop the rotation of the end effector 7000. Similarly, thedetectable element closes the switch of the second sensor when theannular ring 1422 is rotated in the second direction from the centerposition. When the switch of the second sensor is closed, the controlsystem 1800 operates the electric motor 1610 to rotate the end effector7000 in the second direction. When the annular ring 1422 is rotated inthe first direction toward the center position, the detectable elementis disengaged from the second switch and the second switch is re-opened.Once the second switch is re-opened, the control system 1800 cuts thepower to the electric motor 1610 to stop the rotation of the endeffector 7000.

In various embodiments, further to the above, the first and secondsensors of the rotation actuator 1420 comprise proximity sensors, forexample. In certain embodiments, the first and second sensors of therotation actuator 1420 comprise Hall Effect sensors, and/or any suitablesensors, configured to detect the distance between the detectableelement of the annular ring 1422 and the first and second sensors. Ifthe first Hall Effect sensor detects that the annular ring 1422 has beenrotated in the first direction, then, as discussed above, the controlsystem 1800 will rotate the end effector 7000 in the first direction. Inaddition, the control system 1800 can rotate the end effector 7000 at afaster speed when the detectable element is closer to the first HallEffect sensor than when the detectable element is further away from thefirst Hall Effect sensor. If the second Hall Effect sensor detects thatthe annular ring 1422 has been rotated in the second direction, then, asdiscussed above, the control system 1800 will rotate the end effector7000 in the second direction. In addition, the control system 1800 canrotate the end effector 7000 at a faster speed when the detectableelement is closer to the second Hall Effect sensor than when thedetectable element is further away from the second Hall Effect sensor.As a result, the speed in which the end effector 7000 is rotated is afunction of the amount, or degree, in which the annular ring 1422 isrotated. The control system 1800 is further configured to evaluate theinputs from both the first and second Hall Effect sensors whendetermining the direction and speed in which to rotate the end effector7000. In various instances, the control system 1800 can use the closestHall Effect sensor to the detectable element of the annular ring 1422 asa primary source of data and the Hall Effect sensor furthest away fromthe detectable element as a confirmational source of data todouble-check the data provided by the primary source of data. Thecontrol system 1800 can further comprise a data integrity protocol toresolve situations in which the control system 1800 is provided withconflicting data. In any event, the handle control system 1800 can enterinto a neutral state in which the handle control system 1800 does notrotate the end effector 7000 when the Hall Effect sensors detect thatthe detectable element is in its center position, or in a position whichis equidistant between the first Hall Effect sensor and the second HallEffect sensor. In at least one such instance, the control system 1800can enter into its neutral state when the detectable element is in acentral range of positions. Such an arrangement would prevent, or atleast reduce the possibility of, rotational jitter when the clinician isnot intending to rotate the end effector 7000.

Further to the above, the rotation actuator 1420 can comprise one ormore springs configured to center, or at least substantially center, therotation actuator 1420 when it is released by the clinician. In suchinstances, the springs can act to shut off the electric motor 1610 andstop the rotation of the end effector 7000. In at least one instance,the rotation actuator 1420 comprises a first torsion spring configuredto rotate the rotation actuator 1420 in the first direction and a secondtorsion spring configured to rotate the rotation actuator 1420 in thesecond direction. The first and second torsion springs can have thesame, or at least substantially the same, spring constant such that theforces and/or torques applied by the first and second torsion springsbalance, or at least substantially balance, the rotation actuator 1420in its center position.

In view of the above, the reader should appreciate that the clampingtrigger 2610 and the rotation actuator 1420 are both operable to rotatethe drive shaft 2710 and either, respectively, operate the jaw assembly7100 or rotate the end effector 7000. The system that uses the rotationof the drive shaft 2710 to selectively perform these functions isdescribed in greater detail below.

Referring to FIGS. 7 and 8, the articulation actuator 1430 comprises afirst push button 1432 and a second push button 1434. The first pushbutton 1432 is part of a first articulation control circuit and thesecond push button 1434 is part of a second articulation circuit of theinput system 1400. The first push button 1432 comprises a first switchthat is closed when the first push button 1432 is depressed. The handlecontrol system 1800 is configured to sense the closure of the firstswitch and, moreover, the closure of the first articulation controlcircuit. When the handle control system 1800 detects that the firstarticulation control circuit has been closed, the handle control system1800 operates the electric motor 1610 to articulate the end effector7000 in a first articulation direction about the articulation joint2300. When the first push button 1432 is released by the clinician, thefirst articulation control circuit is opened which, once detected by thecontrol system 1800, causes the control system 1800 to cut the power tothe electric motor 1610 to stop the articulation of the end effector7000.

In various instances, further to the above, the articulation range ofthe end effector 7000 is limited and the control system 1800 can utilizethe encoder system discussed above for monitoring the rotational outputof the electric motor 1610, for example, to monitor the amount, ordegree, in which the end effector 7000 is rotated in the firstdirection. In addition to or in lieu of the encoder system, the shaftassembly 2000 can comprise a first sensor configured to detect when theend effector 7000 has reached the limit of its articulation in the firstdirection. In any event, when the control system 1800 determines thatthe end effector 7000 has reached the limit of articulation in the firstdirection, the control system 1800 can cut the power to the electricmotor 1610 to stop the articulation of the end effector 7000.

Similar to the above, the second push button 1434 comprises a secondswitch that is closed when the second push button 1434 is depressed. Thehandle control system 1800 is configured to sense the closure of thesecond switch and, moreover, the closure of the second articulationcontrol circuit. When the handle control system 1800 detects that thesecond articulation control circuit has been closed, the handle controlsystem 1800 operates the electric motor 1610 to articulate the endeffector 7000 in a second direction about the articulation joint 2300.When the second push button 1434 is released by the clinician, thesecond articulation control circuit is opened which, once detected bythe control system 1800, causes the control system 1800 to cut the powerto the electric motor 1610 to stop the articulation of the end effector7000.

In various instances, the articulation range of the end effector 7000 islimited and the control system 1800 can utilize the encoder systemdiscussed above for monitoring the rotational output of the electricmotor 1610, for example, to monitor the amount, or degree, in which theend effector 7000 is rotated in the second direction. In addition to orin lieu of the encoder system, the shaft assembly 2000 can comprise asecond sensor configured to detect when the end effector 7000 hasreached the limit of its articulation in the second direction. In anyevent, when the control system 1800 determines that the end effector7000 has reached the limit of articulation in the second direction, thecontrol system 1800 can cut the power to the electric motor 1610 to stopthe articulation of the end effector 7000.

As described above, the end effector 7000 is articulatable in a firstdirection (FIG. 16) and/or a second direction (FIG. 17) from a center,or unarticulated, position (FIG. 15). Once the end effector 7000 hasbeen articulated, the clinician can attempt to re-center the endeffector 7000 by using the first and second articulation push buttons1432 and 1434. As the reader can appreciate, the clinician may struggleto re-center the end effector 7000 as, for instance, the end effector7000 may not be entirely visible once it is positioned in the patient.In some instances, the end effector 7000 may not fit back through atrocar if the end effector 7000 is not re-centered, or at leastsubstantially re-centered. With that in mind, the control system 1800 isconfigured to provide feedback to the clinician when the end effector7000 is moved into its unarticulated, or centered, position. In at leastone instance, the feedback comprises audio feedback and the handlecontrol system 1800 can comprise a speaker which emits a sound, such asa beep, for example, when the end effector 7000 is centered. In certaininstances, the feedback comprises visual feedback and the handle controlsystem 1800 can comprise a light emitting diode (LED), for example,positioned on the handle housing 1110 which flashes when the endeffector 7000 is centered. In various instances, the feedback compriseshaptic feedback and the handle control system 1800 can comprise anelectric motor comprising an eccentric element which vibrates the handle1000 when the end effector 7000 is centered. Manually re-centering theend effector 7000 in this way can be facilitated by the control system1800 slowing the motor 1610 when the end effector 7000 is approachingits centered position. In at least one instance, the control system 1800slows the articulation of the end effector 7000 when the end effector7000 is within approximately 5 degrees of center in either direction,for example.

In addition to or in lieu of the above, the handle control system 1800can be configured to re-center the end effector 7000. In at least onesuch instance, the handle control system 1800 can re-center the endeffector 7000 when both of the articulation buttons 1432 and 1434 of thearticulation actuator 1430 are depressed at the same time. When thehandle control system 1800 comprises an encoder system configured tomonitor the rotational output of the electric motor 1610, for example,the handle control system 1800 can determine the amount and direction ofarticulation needed to re-center, or at least substantially re-center,the end effector 7000. In various instances, the input system 1400 cancomprise a home button, for example, which, when depressed,automatically centers the end effector 7000.

Referring primarily to FIGS. 5 and 6, the elongate shaft 2200 of theshaft assembly 2000 comprises an outer housing, or tube, 2210 mounted tothe proximal housing 2110 of the proximal portion 2100. The outerhousing 2210 comprises a longitudinal aperture 2230 extendingtherethrough and a proximal flange 2220 which secures the outer housing2210 to the proximal housing 2110. The frame 2500 of the shaft assembly2000 extends through the longitudinal aperture 2230 of the elongateshaft 2200. More specifically, the shaft 2510 of the shaft frame 2500necks down into a smaller shaft 2530 which extends through thelongitudinal aperture 2230. That said, the shaft frame 2500 can compriseany suitable arrangement. The drive system 2700 of the shaft assembly2000 also extends through the longitudinal aperture 2230 of the elongateshaft 2200. More specifically, the drive shaft 2710 of the shaft drivesystem 2700 necks down into a smaller drive shaft 2730 which extendsthrough the longitudinal aperture 2230. That said, the shaft drivesystem 2700 can comprise any suitable arrangement.

Referring primarily to FIGS. 20, 23, and 24, the outer housing 2210 ofthe elongate shaft 2200 extends to the articulation joint 2300. Thearticulation joint 2300 comprises a proximal frame 2310 mounted to theouter housing 2210 such that there is little, if any, relativetranslation and/or rotation between the proximal frame 2310 and theouter housing 2210. Referring primarily to FIG. 22, the proximal frame2310 comprises an annular portion 2312 mounted to the sidewall of theouter housing 2210 and tabs 2314 extending distally from the annularportion 2312. The articulation joint 2300 further comprises links 2320and 2340 which are rotatably mounted to the frame 2310 and mounted to anouter housing 2410 of the distal attachment portion 2400. The link 2320comprises a distal end 2322 mounted to the outer housing 2410. Morespecifically, the distal end 2322 of the link 2320 is received andfixedly secured within a mounting slot 2412 defined in the outer housing2410. Similarly, the link 2340 comprises a distal end 2342 mounted tothe outer housing 2410. More specifically, the distal end 2342 of thelink 2340 is received and fixedly secured within a mounting slot definedin the outer housing 2410. The link 2320 comprises a proximal end 2324rotatably coupled to a tab 2314 of the proximal articulation frame 2310.Although not illustrated in FIG. 22, a pin extends through aperturesdefined in the proximal end 2324 and the tab 2314 to define a pivot axistherebetween. Similarly, the link 2340 comprises a proximal end 2344rotatably coupled to a tab 2314 of the proximal articulation frame 2310.Although not illustrated in FIG. 22, a pin extends through aperturesdefined in the proximal end 2344 and the tab 2314 to define a pivot axistherebetween. These pivot axes are collinear, or at least substantiallycollinear, and define an articulation axis A of the articulation joint2300.

Referring primarily to FIGS. 20, 23, and 24, the outer housing 2410 ofthe distal attachment portion 2400 comprises a longitudinal aperture2430 extending therethrough. The longitudinal aperture 2430 isconfigured to receive a proximal attachment portion 7400 of the endeffector 7000. The end effector 7000 comprises an outer housing 6230which is closely received within the longitudinal aperture 2430 of thedistal attachment portion 2400 such that there is little, if any,relative radial movement between the proximal attachment portion 7400 ofthe end effector 7000 and the distal attachment portion 2400 of theshaft assembly 2000. The proximal attachment portion 7400 furthercomprises an annular array of lock notches 7410 defined on the outerhousing 6230 which is releasably engaged by an end effector lock 6400 inthe distal attachment portion 2400 of the shaft assembly 2000. When theend effector lock 6400 is engaged with the array of lock notches 7410,the end effector lock 6400 prevents, or at least inhibits, relativelongitudinal movement between the proximal attachment portion 7400 ofthe end effector 7000 and the distal attachment portion 2400 of theshaft assembly 2000. As a result of the above, only relative rotationbetween the proximal attachment portion 7400 of the end effector 7000and the distal attachment portion 2400 of the shaft assembly 2000 ispermitted. To this end, the outer housing 6230 of the end effector 7000is closely received within the longitudinal aperture 2430 defined in thedistal attachment portion 2400 of the shaft assembly 2000.

Further to the above, referring to FIG. 21, the outer housing 6230further comprises an annular slot, or recess, 6270 defined therein whichis configured to receive an O-ring 6275 therein. The O-ring 6275 iscompressed between the outer housing 6230 and the sidewall of thelongitudinal aperture 2430 when the end effector 7000 is inserted intothe distal attachment portion 2400. The O-ring 6275 is configured toresist, but permit, relative rotation between the end effector 7000 andthe distal attachment portion 2400 such that the O-ring 6275 canprevent, or reduce the possibility of, unintentional relative rotationbetween the end effector 7000 and the distal attachment portion 2400. Invarious instances, the O-ring 6275 can provide a seal between the endeffector 7000 and the distal attachment portion 2400 to prevent, or atleast reduce the possibility of, fluid ingress into the shaft assembly2000, for example.

Referring to FIGS. 14-21, the jaw assembly 7100 of the end effector 7000comprises a first jaw 7110 and a second jaw 7120. Each jaw 7110, 7120comprises a distal end which is configured to assist a clinician indissecting tissue with the end effector 7000. Each jaw 7110, 7120further comprises a plurality of teeth which are configured to assist aclinician in grasping and holding onto tissue with the end effector7000. Moreover, referring primarily to FIG. 21, each jaw 7110, 7120comprises a proximal end, i.e., proximal ends 7115, 7125, respectively,which rotatably connect the jaws 7110, 7120 together. Each proximal end7115, 7125 comprises an aperture extending therethrough which isconfigured to closely receive a pin 7130 therein. The pin 7130 comprisesa central body 7135 closely received within the apertures defined in theproximal ends 7115, 7125 of the jaws 7110, 7120 such that there islittle, if any, relative translation between the jaws 7110, 7120 and thepin 7130. The pin 7130 defines a jaw axis J about which the jaws 7110,7120 can be rotated and, also, rotatably mounts the jaws 7110, 7120 tothe outer housing 6230 of the end effector 7000. More specifically, theouter housing 6230 comprises distally-extending tabs 6235 havingapertures defined therein which are also configured to closely receivethe pin 7130 such that the jaw assembly 7100 does not translate relativeto a shaft portion 7200 of the end effector 7000. The pin 7130 furthercomprises enlarged ends which prevent the jaws 7110, 7120 from becomingdetached from the pin 7130 and also prevents the jaw assembly 7100 frombecoming detached from the shaft portion 7200. This arrangement definesa rotation joint 7300.

Referring primarily to FIGS. 21 and 23, the jaws 7110 and 7120 arerotatable between their open and closed positions by a jaw assemblydrive including drive links 7140, a drive nut 7150, and a drive screw6130. As described in greater detail below, the drive screw 6130 isselectively rotatable by the drive shaft 2730 of the shaft drive system2700. The drive screw 6130 comprises an annular flange 6132 which isclosely received within a slot, or groove, 6232 (FIG. 25) defined in theouter housing 6230 of the end effector 7000. The sidewalls of the slot6232 are configured to prevent, or at least inhibit, longitudinal and/orradial translation between the drive screw 6130 and the outer housing6230, but yet permit relative rotational motion between the drive screw6130 and the outer housing 6230. The drive screw 6130 further comprisesa threaded end 6160 which is threadably engaged with a threaded aperture7160 defined in the drive nut 7150. The drive nut 7150 is constrainedfrom rotating with the drive screw 6130 and, as a result, the drive nut7150 is translated when the drive screw 6130 is rotated. In use, thedrive screw 6130 is rotated in a first direction to displace the drivenut 7150 proximally and in a second, or opposite, direction to displacethe drive nut 7150 distally. The drive nut 7150 further comprises adistal end 7155 comprising an aperture defined therein which isconfigured to closely receive pins 7145 extending from the drive links7140. Referring primarily to FIG. 21, a first drive link 7140 isattached to one side of the distal end 7155 and a second drive link 7140is attached to the opposite side of the distal end 7155. The first drivelink 7140 comprises another pin 7145 extending therefrom which isclosely received in an aperture defined in the proximal end 7115 of thefirst jaw 7110 and, similarly, the second drive link 7140 comprisesanother pin extending therefrom which is closely received in an aperturedefined in the proximal end 7125 of the second jaw 7120. As a result ofthe above, the drive links 7140 operably connect the jaws 7110 and 7120to the drive nut 7150. When the drive nut 7150 is driven proximally bythe drive screw 6130, as described above, the jaws 7110, 7120 arerotated into the closed, or clamped, configuration. Correspondingly, thejaws 7110, 7120 are rotated into their open configuration when the drivenut 7150 is driven distally by the drive screw 6130.

As discussed above, the control system 1800 is configured to actuate theelectric motor 1610 to perform three different end effectorfunctions—clamping/opening the jaw assembly 7100 (FIGS. 14 and 15),rotating the end effector 7000 about a longitudinal axis (FIGS. 18 and19), and articulating the end effector 7000 about an articulation axis(FIGS. 16 and 17). Referring primarily to FIGS. 26 and 27, the controlsystem 1800 is configured to operate a transmission 6000 to selectivelyperform these three end effector functions. The transmission 6000comprises a first clutch system 6100 configured to selectively transmitthe rotation of the drive shaft 2730 to the drive screw 6130 of the endeffector 7000 to open or close the jaw assembly 7100, depending on thedirection in which the drive shaft 2730 is rotated. The transmission6000 further comprises a second clutch system 6200 configured toselectively transmit the rotation of the drive shaft 2730 to the outerhousing 6230 of the end effector 7000 to rotate the end effector 7000about the longitudinal axis L. The transmission 6000 also comprises athird clutch system 6300 configured to selectively transmit the rotationof the drive shaft 2730 to the articulation joint 2300 to articulate thedistal attachment portion 2400 and the end effector 7000 about thearticulation axis A. The clutch systems 6100, 6200, and 6300 are inelectrical communication with the control system 1800 via electricalcircuits extending through the shaft 2510, the connector pins 2520, theconnector pins 1520, and the shaft 1510, for example. In at least oneinstance, each of these clutch control circuits comprises two connectorpins 2520 and two connector pins 1520, for example.

In various instances, further to the above, the shaft 2510 and/or theshaft 1510 comprise a flexible circuit including electrical traces whichform part of the clutch control circuits. The flexible circuit cancomprise a ribbon, or substrate, with conductive pathways definedtherein and/or thereon. The flexible circuit can also comprise sensorsand/or any solid state component, such as signal smoothing capacitors,for example, mounted thereto. In at least one instance, each of theconductive pathways can comprise one or more signal smoothing capacitorswhich can, among other things, even out fluctuations in signalstransmitted through the conductive pathways. In various instances, theflexible circuit can be coated with at least one material, such as anelastomer, for example, which can seal the flexible circuit againstfluid ingress.

Referring primarily to FIG. 28, the first clutch system 6100 comprises afirst clutch 6110, an expandable first drive ring 6120, and a firstelectromagnetic actuator 6140. The first clutch 6110 comprises anannular ring and is slideably disposed on the drive shaft 2730. Thefirst clutch 6110 is comprised of a magnetic material and is movablebetween a disengaged, or unactuated, position (FIG. 28) and an engaged,or actuated, position (FIG. 29) by electromagnetic fields EF generatedby the first electromagnetic actuator 6140. In various instances, thefirst clutch 6110 is at least partially comprised of iron and/or nickel,for example. In at least one instance, the first clutch 6110 comprises apermanent magnet. As illustrated in FIG. 22A, the drive shaft 2730comprises one or more longitudinal key slots 6115 defined therein whichare configured to constrain the longitudinal movement of the clutch 6110relative to the drive shaft 2730. More specifically, the clutch 6110comprises one or more keys extending into the key slots 6115 such thatthe distal ends of the key slots 6115 stop the distal movement of theclutch 6110 and the proximal ends of the key slots 6115 stop theproximal movement of the clutch 6110.

When the first clutch 6110 is in its disengaged position (FIG. 28), thefirst clutch 6110 rotates with the drive shaft 2130 but does nottransmit rotational motion to the first drive ring 6120. As can be seenin FIG. 28, the first clutch 6110 is separated from, or not in contactwith, the first drive ring 6120. As a result, the rotation of the driveshaft 2730 and the first clutch 6110 is not transmitted to the drivescrew 6130 when the first clutch assembly 6100 is in its disengagedstate. When the first clutch 6110 is in its engaged position (FIG. 29),the first clutch 6110 is engaged with the first drive ring 6120 suchthat the first drive ring 6120 is expanded, or stretched, radiallyoutwardly into contact with the drive screw 6130. In at least oneinstance, the first drive ring 6120 comprises an elastomeric band, forexample. As can be seen in FIG. 29, the first drive ring 6120 iscompressed against an annular inner sidewall 6135 of the drive screw6130. As a result, the rotation of the drive shaft 2730 and the firstclutch 6110 is transmitted to the drive screw 6130 when the first clutchassembly 6100 is in its engaged state. Depending on the direction inwhich the drive shaft 2730 is rotated, the first clutch assembly 6100can move the jaw assembly 7100 into its open and closed configurationswhen the first clutch assembly 6100 is in its engaged state.

As described above, the first electromagnetic actuator 6140 isconfigured to generate magnetic fields to move the first clutch 6110between its disengaged (FIG. 28) and engaged (FIG. 29) positions. Forinstance, referring to FIG. 28, the first electromagnetic actuator 6140is configured to emit a magnetic field EF_(L) which repulses, or drives,the first clutch 6110 away from the first drive ring 6120 when the firstclutch assembly 6100 is in its disengaged state. The firstelectromagnetic actuator 6140 comprises one or more wound coils in acavity defined in the shaft frame 2530 which generate the magnetic fieldEF_(L) when current flows in a first direction through a firstelectrical clutch circuit including the wound coils. The control system1800 is configured to apply a first voltage polarity to the firstelectrical clutch circuit to create the current flowing in the firstdirection. The control system 1800 can continuously apply the firstvoltage polarity to the first electric shaft circuit to continuouslyhold the first clutch 6110 in its disengaged position. While such anarrangement can prevent the first clutch 6110 from unintentionallyengaging the first drive ring 6120, such an arrangement can also consumea lot of power. Alternatively, the control system 1800 can apply thefirst voltage polarity to the first electrical clutch circuit for asufficient period of time to position the first clutch 6110 in itsdisengaged position and then discontinue applying the first voltagepolarity to the first electric clutch circuit, thereby resulting in alower consumption of power. That being said, the first clutch assembly6100 further comprises a first clutch lock 6150 mounted in the drivescrew 6130 which is configured to releasably hold the first clutch 6110in its disengaged position. The first clutch lock 6150 is configured toprevent, or at least reduce the possibility of, the first clutch 6110from becoming unintentionally engaged with the first drive ring 6120.When the first clutch 6110 is in its disengaged position, as illustratedin FIG. 28, the first clutch lock 6150 interferes with the free movementof the first clutch 6110 and holds the first clutch 6110 in position viaa friction force and/or an interference force therebetween. In at leastone instance, the first clutch lock 6150 comprises an elastomeric plug,seat, or detent, comprised of rubber, for example. In certain instances,the first clutch lock 6150 comprises a permanent magnet which holds thefirst clutch 6110 in its disengaged position by an electromagneticforce. In any event, the first electromagnetic actuator 6140 can applyan electromagnetic pulling force to the first clutch 6110 that overcomesthese forces, as described in greater detail below.

Further to the above, referring to FIG. 29, the first electromagneticactuator 6140 is configured to emit a magnetic field EF_(D) which pulls,or drives, the first clutch 6110 toward the first drive ring 6120 whenthe first clutch assembly 6100 is in its engaged state. The coils of thefirst electromagnetic actuator 6140 generate the magnetic field EF_(D)when current flows in a second, or opposite, direction through the firstelectrical clutch circuit. The control system 1800 is configured toapply an opposite voltage polarity to the first electrical clutchcircuit to create the current flowing in the opposite direction. Thecontrol system 1800 can continuously apply the opposite voltage polarityto the first electrical clutch circuit to continuously hold the firstclutch 6110 in its engaged position and maintain the operable engagementbetween the first drive ring 6120 and the drive screw 6130.Alternatively, the first clutch 6110 can be configured to become wedgedwithin the first drive ring 6120 when the first clutch 6110 is in itsengaged position and, in such instances, the control system 1800 may notneed to continuously apply a voltage polarity to the first electricalclutch circuit to hold the first clutch assembly 6100 in its engagedstate. In such instances, the control system 1800 can discontinueapplying the voltage polarity once the first clutch 6110 has beensufficiently wedged in the first drive ring 6120.

Notably, further to the above, the first clutch lock 6150 is alsoconfigured to lockout the jaw assembly drive when the first clutch 6110is in its disengaged position. More specifically, referring again toFIG. 28, the first clutch 6110 pushes the first clutch lock 6150 in thedrive screw 6130 into engagement with the outer housing 6230 of the endeffector 7000 when the first clutch 6110 is in its disengaged positionsuch that the drive screw 6130 does not rotate, or at leastsubstantially rotate, relative to the outer housing 6230. The outerhousing 6230 comprises a slot 6235 defined therein which is configuredto receive the first clutch lock 6150. When the first clutch 6110 ismoved into its engaged position, referring to FIG. 29, the first clutch6110 is no longer engaged with the first clutch lock 6150 and, as aresult, the first clutch lock 6150 is no longer biased into engagementwith the outer housing 6230 and the drive screw 6130 can rotate freelywith respect to the outer housing 6230. As a result of the above, thefirst clutch 6110 can do at least two things—operate the jaw drive whenthe first clutch 6110 is in its engaged position and lock out the jawdrive when the first clutch 6110 is in its disengaged position.

Moreover, further to the above, the threads of the threaded portions6160 and 7160 can be configured to prevent, or at least resist,backdriving of the jaw drive. In at least one instance, the thread pitchand/or angle of the threaded portions 6160 and 7160, for example, can beselected to prevent the backdriving, or unintentional opening, of thejaw assembly 7100. As a result of the above, the possibility of the jawassembly 7100 unintentionally opening or closing is prevented, or atleast reduced.

Referring primarily to FIG. 30, the second clutch system 6200 comprisesa second clutch 6210, an expandable second drive ring 6220, and a secondelectromagnetic actuator 6240. The second clutch 6210 comprises anannular ring and is slideably disposed on the drive shaft 2730. Thesecond clutch 6210 is comprised of a magnetic material and is movablebetween a disengaged, or unactuated, position (FIG. 30) and an engaged,or actuated, position (FIG. 31) by electromagnetic fields EF generatedby the second electromagnetic actuator 6240. In various instances, thesecond clutch 6210 is at least partially comprised of iron and/ornickel, for example. In at least one instance, the second clutch 6210comprises a permanent magnet. As illustrated in FIG. 22A, the driveshaft 2730 comprises one or more longitudinal key slots 6215 definedtherein which are configured to constrain the longitudinal movement ofthe second clutch 6210 relative to the drive shaft 2730. Morespecifically, the second clutch 6210 comprises one or more keysextending into the key slots 6215 such that the distal ends of the keyslots 6215 stop the distal movement of the second clutch 6210 and theproximal ends of the key slots 6215 stop the proximal movement of thesecond clutch 6210.

When the second clutch 6210 is in its disengaged position, referring toFIG. 30, the second clutch 6210 rotates with the drive shaft 2730 butdoes not transmit rotational motion to the second drive ring 6220. Ascan be seen in FIG. 30, the second clutch 6210 is separated from, or notin contact with, the second drive ring 6220. As a result, the rotationof the drive shaft 2730 and the second clutch 6210 is not transmitted tothe outer housing 6230 of the end effector 7000 when the second clutchassembly 6200 is in its disengaged state. When the second clutch 6210 isin its engaged position (FIG. 31), the second clutch 6210 is engagedwith the second drive ring 6220 such that the second drive ring 6220 isexpanded, or stretched, radially outwardly into contact with the outerhousing 6230. In at least one instance, the second drive ring 6220comprises an elastomeric band, for example. As can be seen in FIG. 31,the second drive ring 6220 is compressed against an annular innersidewall 7415 of the outer housing 6230. As a result, the rotation ofthe drive shaft 2730 and the second clutch 6210 is transmitted to theouter housing 6230 when the second clutch assembly 6200 is in itsengaged state. Depending on the direction in which the drive shaft 2730is rotated, the second clutch assembly 6200 can rotate the end effector7000 in a first direction or a second direction about the longitudinalaxis L when the second clutch assembly 6200 is in its engaged state.

As described above, the second electromagnetic actuator 6240 isconfigured to generate magnetic fields to move the second clutch 6210between its disengaged (FIG. 30) and engaged (FIG. 31) positions. Forinstance, the second electromagnetic actuator 6240 is configured to emita magnetic field EF_(L) which repulses, or drives, the second clutch6210 away from the second drive ring 6220 when the second clutchassembly 6200 is in its disengaged state. The second electromagneticactuator 6240 comprises one or more wound coils in a cavity defined inthe shaft frame 2530 which generate the magnetic field EF_(L) whencurrent flows in a first direction through a second electrical clutchcircuit including the wound coils. The control system 1800 is configuredto apply a first voltage polarity to the second electrical clutchcircuit to create the current flowing in the first direction. Thecontrol system 1800 can continuously apply the first voltage polarity tothe second electric clutch circuit to continuously hold the secondclutch 6120 in its disengaged position. While such an arrangement canprevent the second clutch 6210 from unintentionally engaging the seconddrive ring 6220, such an arrangement can also consume a lot of power.Alternatively, the control system 1800 can apply the first voltagepolarity to the second electrical clutch circuit for a sufficient periodof time to position the second clutch 6210 in its disengaged positionand then discontinue applying the first voltage polarity to the secondelectric clutch circuit, thereby resulting in a lower consumption ofpower. That being said, the second clutch assembly 6200 furthercomprises a second clutch lock 6250 mounted in the outer housing 6230which is configured to releasably hold the second clutch 6210 in itsdisengaged position. Similar to the above, the second clutch lock 6250can prevent, or at least reduce the possibility of, the second clutch6210 from becoming unintentionally engaged with the second drive ring6220. When the second clutch 6210 is in its disengaged position, asillustrated in FIG. 30, the second clutch lock 6250 interferes with thefree movement of the second clutch 6210 and holds the second clutch 6210in position via a friction and/or interference force therebetween. In atleast one instance, the second clutch lock 6250 comprises an elastomericplug, seat, or detent, comprised of rubber, for example. In certaininstances, the second clutch lock 6250 comprises a permanent magnetwhich holds the second clutch 6210 in its disengaged position by anelectromagnetic force. That said, the second electromagnetic actuator6240 can apply an electromagnetic pulling force to the second clutch6210 that overcomes these forces, as described in greater detail below.

Further to the above, referring to FIG. 31, the second electromagneticactuator 6240 is configured to emit a magnetic field EF_(D) which pulls,or drives, the second clutch 6210 toward the second drive ring 6220 whenthe second clutch assembly 6200 is in its engaged state. The coils ofthe second electromagnetic actuator 6240 generate the magnetic fieldEF_(D) when current flows in a second, or opposite, direction throughthe second electrical shaft circuit. The control system 1800 isconfigured to apply an opposite voltage polarity to the secondelectrical shaft circuit to create the current flowing in the oppositedirection. The control system 1800 can continuously apply the oppositevoltage polarity to the second electric shaft circuit to continuouslyhold the second clutch 6210 in its engaged position and maintain theoperable engagement between the second drive ring 6220 and the outerhousing 6230. Alternatively, the second clutch 6210 can be configured tobecome wedged within the second drive ring 6220 when the second clutch6210 is in its engaged position and, in such instances, the controlsystem 1800 may not need to continuously apply a voltage polarity to thesecond shaft electrical circuit to hold the second clutch assembly 6200in its engaged state. In such instances, the control system 1800 candiscontinue applying the voltage polarity once the second clutch 6210has been sufficiently wedged in the second drive ring 6220.

Notably, further to the above, the second clutch lock 6250 is alsoconfigured to lockout the rotation of the end effector 7000 when thesecond clutch 6210 is in its disengaged position. More specifically,referring again to FIG. 30, the second clutch 6210 pushes the secondclutch lock 6250 in the outer shaft 6230 into engagement with thearticulation link 2340 when the second clutch 6210 is in its disengagedposition such that the end effector 7000 does not rotate, or at leastsubstantially rotate, relative to the distal attachment portion 2400 ofthe shaft assembly 2000. As illustrated in FIG. 27, the second clutchlock 6250 is positioned or wedged within a slot, or channel, 2345defined in the articulation link 2340 when the second clutch 6210 is inits disengaged position. As a result of the above, the possibility ofthe end effector 7000 unintentionally rotating is prevented, or at leastreduced. Moreover, as a result of the above, the second clutch 6210 cando at least two things—operate the end effector rotation drive when thesecond clutch 6210 is in its engaged position and lock out the endeffector rotation drive when the second clutch 6210 is in its disengagedposition.

Referring primarily to FIGS. 22, 24, and 25, the shaft assembly 2000further comprises an articulation drive system configured to articulatethe distal attachment portion 2400 and the end effector 7000 about thearticulation joint 2300. The articulation drive system comprises anarticulation drive 6330 rotatably supported within the distal attachmentportion 2400. That said, the articulation drive 6330 is closely receivedwithin the distal attachment portion 2400 such that the articulationdrive 6330 does not translate, or at least substantially translate,relative to the distal attachment portion 2400. The articulation drivesystem of the shaft assembly 2000 further comprises a stationary gear2330 fixedly mounted to the articulation frame 2310. More specifically,the stationary gear 2330 is fixedly mounted to a pin connecting a tab2314 of the articulation frame 2310 and the articulation link 2340 suchthat the stationary gear 2330 does not rotate relative to thearticulation frame 2310. The stationary gear 2330 comprises a centralbody 2335 and an annular array of stationary teeth 2332 extending aroundthe perimeter of the central body 2335. The articulation drive 6330comprises an annular array of drive teeth 6332 which is meshinglyengaged with the stationary teeth 2332. When the articulation drive 6330is rotated, the articulation drive 6330 pushes against the stationarygear 2330 and articulates the distal attachment portion 2400 of theshaft assembly 2000 and the end effector 7000 about the articulationjoint 2300.

Referring primarily to FIG. 32, the third clutch system 6300 comprises athird clutch 6310, an expandable third drive ring 6320, and a thirdelectromagnetic actuator 6340. The third clutch 6310 comprises anannular ring and is slideably disposed on the drive shaft 2730. Thethird clutch 6310 is comprised of a magnetic material and is movablebetween a disengaged, or unactuated, position (FIG. 32) and an engaged,or actuated, position (FIG. 33) by electromagnetic fields EF generatedby the third electromagnetic actuator 6340. In various instances, thethird clutch 6310 is at least partially comprised of iron and/or nickel,for example. In at least one instance, the third clutch 6310 comprises apermanent magnet. As illustrated in FIG. 22A, the drive shaft 2730comprises one or more longitudinal key slots 6315 defined therein whichare configured to constrain the longitudinal movement of the thirdclutch 6310 relative to the drive shaft 2730. More specifically, thethird clutch 6310 comprises one or more keys extending into the keyslots 6315 such that the distal ends of the key slots 6315 stop thedistal movement of the third clutch 6310 and the proximal ends of thekey slots 6315 stop the proximal movement of the third clutch 6310.

When the third clutch 6310 is in its disengaged position, referring toFIG. 32, the third clutch 6310 rotates with the drive shaft 2730 butdoes not transmit rotational motion to the third drive ring 6320. As canbe seen in FIG. 32, the third clutch 6310 is separated from, or not incontact with, the third drive ring 6320. As a result, the rotation ofthe drive shaft 2730 and the third clutch 6310 is not transmitted to thearticulation drive 6330 when the third clutch assembly 6300 is in itsdisengaged state. When the third clutch 6310 is in its engaged position,referring to FIG. 33, the third clutch 6310 is engaged with the thirddrive ring 6320 such that the third drive ring 6320 is expanded, orstretched, radially outwardly into contact with the articulation drive6330. In at least one instance, the third drive ring 6320 comprises anelastomeric band, for example. As can be seen in FIG. 33, the thirddrive ring 6320 is compressed against an annular inner sidewall 6335 ofthe articulation drive 6330. As a result, the rotation of the driveshaft 2730 and the third clutch 6310 is transmitted to the articulationdrive 6330 when the third clutch assembly 6300 is in its engaged state.Depending on the direction in which the drive shaft 2730 is rotated, thethird clutch assembly 6300 can articulate the distal attachment portion2400 of the shaft assembly 2000 and the end effector 7000 in a first orsecond direction about the articulation joint 2300.

As described above, the third electromagnetic actuator 6340 isconfigured to generate magnetic fields to move the third clutch 6310between its disengaged (FIG. 32) and engaged (FIG. 33) positions. Forinstance, referring to FIG. 32, the third electromagnetic actuator 6340is configured to emit a magnetic field EF_(L) which repulses, or drives,the third clutch 6310 away from the third drive ring 6320 when the thirdclutch assembly 6300 is in its disengaged state. The thirdelectromagnetic actuator 6340 comprises one or more wound coils in acavity defined in the shaft frame 2530 which generate the magnetic fieldEF_(L) when current flows in a first direction through a thirdelectrical clutch circuit including the wound coils. The control system1800 is configured to apply a first voltage polarity to the thirdelectrical clutch circuit to create the current flowing in the firstdirection. The control system 1800 can continuously apply the firstvoltage polarity to the third electric clutch circuit to continuouslyhold the third clutch 6310 in its disengaged position. While such anarrangement can prevent the third clutch 6310 from unintentionallyengaging the third drive ring 6320, such an arrangement can also consumea lot of power. Alternatively, the control system 1800 can apply thefirst voltage polarity to the third electrical clutch circuit for asufficient period of time to position the third clutch 6310 in itsdisengaged position and then discontinue applying the first voltagepolarity to the third electric clutch circuit, thereby resulting in alower consumption of power.

Further to the above, the third electromagnetic actuator 6340 isconfigured to emit a magnetic field EF_(D) which pulls, or drives, thethird clutch 6310 toward the third drive ring 6320 when the third clutchassembly 6300 is in its engaged state. The coils of the thirdelectromagnetic actuator 6340 generate the magnetic field EF_(D) whencurrent flows in a second, or opposite, direction through the thirdelectrical clutch circuit. The control system 1800 is configured toapply an opposite voltage polarity to the third electrical shaft circuitto create the current flowing in the opposite direction. The controlsystem 1800 can continuously apply the opposite voltage polarity to thethird electric shaft circuit to continuously hold the third clutch 6310in its engaged position and maintain the operable engagement between thethird drive ring 6320 and the articulation drive 6330. Alternatively,the third clutch 6210 can be configured to become wedged within thethird drive ring 6320 when the third clutch 6310 is in its engagedposition and, in such instances, the control system 1800 may not need tocontinuously apply a voltage polarity to the third shaft electricalcircuit to hold the third clutch assembly 6300 in its engaged state. Insuch instances, the control system 1800 can discontinue applying thevoltage polarity once the third clutch 6310 has been sufficiently wedgedin the third drive ring 6320. In any event, the end effector 7000 isarticulatable in a first direction or a second direction, depending onthe direction in which the drive shaft 2730 is rotated, when the thirdclutch assembly 6300 is in its engaged state.

Further to the above, referring to FIGS. 22, 32, and 33, thearticulation drive system further comprises a lockout 6350 whichprevents, or at least inhibits, the articulation of the distalattachment portion 2400 of the shaft assembly 2000 and the end effector7000 about the articulation joint 2300 when the third clutch 6310 is inits disengaged position (FIG. 32). Referring primarily to FIG. 22, thearticulation link 2340 comprises a slot, or groove, 2350 defined thereinwherein the lockout 6350 is slideably positioned in the slot 2350 andextends at least partially under the stationary articulation gear 2330.The lockout 6350 comprises at attachment hook 6352 engaged with thethird clutch 6310. More specifically, the third clutch 6310 comprises anannular slot, or groove, 6312 defined therein and the attachment hook6352 is positioned in the annular slot 6312 such that the lockout 6350translates with the third clutch 6310. Notably, however, the lockout6350 does not rotate, or at least substantially rotate, with the thirdclutch 6310. Instead, the annular groove 6312 in the third clutch 6310permits the third clutch 6310 to rotate relative to the lockout 6350.The lockout 6350 further comprises a lockout hook 6354 slideablypositioned in a radially-extending lockout slot 2334 defined in thebottom of the stationary gear 2330. When the third clutch 6310 is in itsdisengaged position, as illustrated in FIG. 32, the lockout 6350 is in alocked position in which the lockout hook 6354 prevents the end effector7000 from rotating about the articulation joint 2300. When the thirdclutch 6310 is in its engaged position, as illustrated in FIG. 33, thelockout 6350 is in an unlocked position in which the lockout hook 6354is no longer positioned in the lockout slot 2334. Instead, the lockouthook 6354 is positioned in a clearance slot defined in the middle orbody 2335 of the stationary gear 2330. In such instances, the lockouthook 6354 can rotate within the clearance slot when the end effector7000 rotates about the articulation joint 2300.

Further to the above, the radially-extending lockout slot 2334 depictedin FIGS. 32 and 33 extends longitudinally, i.e., along an axis which isparallel to the longitudinal axis of the elongate shaft 2200. Once theend effector 7000 has been articulated, however, the lockout hook 6354is no longer aligned with the longitudinal lockout slot 2334. With thisin mind, the stationary gear 2330 comprises a plurality, or an array, ofradially-extending lockout slots 2334 defined in the bottom of thestationary gear 2330 such that, when the third clutch 6310 is deactuatedand the lockout 6350 is pulled distally after the end effector 7000 hasbeen articulated, the lockout hook 6354 can enter one of the lockoutslots 2334 and lock the end effector 7000 in its articulated position.Thus, as a result, the end effector 7000 can be locked in anunarticulated and an articulated position. In various instances, thelockout slots 2334 can define discrete articulated positions for the endeffector 7000. For instance, the lockout slots 2334 can be defined at 10degree intervals, for example, which can define discrete articulationorientations for the end effector 7000 at 10 degree intervals. In otherinstances, these orientations can be at 5 degree intervals, for example.In alternative embodiments, the lockout 6350 comprises a brake thatengages a circumferential shoulder defined in the stationary gear 2330when the third clutch 6310 is disengaged from the third drive ring 6320.In such an embodiment, the end effector 7000 can be locked in anysuitable orientation. In any event, the lockout 6350 prevents, or atleast reduces the possibility of, the end effector 7000 unintentionallyarticulating. As a result of the above, the third clutch 6310 can dothings—operate the articulation drive when it is in its engaged positionand lock out the articulation drive when it is in its disengagedposition.

Referring primarily to FIGS. 24 and 25, the shaft frame 2530 and thedrive shaft 2730 extend through the articulation joint 2300 into thedistal attachment portion 2400. When the end effector 7000 isarticulated, as illustrated in FIGS. 16 and 17, the shaft frame 2530 andthe drive shaft 2730 bend to accommodate the articulation of the endeffector 7000. Thus, the shaft frame 2530 and the drive shaft 2730 arecomprised of any suitable material which accommodates the articulationof the end effector 7000. Moreover, as discussed above, the shaft frame2530 houses the first, second, and third electromagnetic actuators 6140,6240, and 6340. In various instances, the first, second, and thirdelectromagnetic actuators 6140, 6240, and 6340 each comprise wound wirecoils, such as copper wire coils, for example, and the shaft frame 2530is comprised of an insulative material to prevent, or at least reducethe possibility of, short circuits between the first, second, and thirdelectromagnetic actuators 6140, 6240, and 6340. In various instances,the first, second, and third electrical clutch circuits extendingthrough the shaft frame 2530 are comprised of insulated electricalwires, for example. Further to the above, the first, second, and thirdelectrical clutch circuits place the electromagnetic actuators 6140,6240, and 6340 in communication with the control system 1800 in thedrive module 1100.

As described above, the clutches 6110, 6210, and/or 6310 can be held intheir disengaged positions so that they do not unintentionally move intotheir engaged positions. In various arrangements, the clutch system 6000comprises a first biasing member, such as a spring, for example,configured to bias the first clutch 6110 into its disengaged position, asecond biasing member, such as a spring, for example, configured to biasthe second clutch 6210 into its disengaged position, and/or a thirdbiasing member, such as a spring, for example, configured to bias thethird clutch 6110 into its disengaged position. In such arrangements,the biasing forces of the springs can be selectively overcome by theelectromagnetic forces generated by the electromagnetic actuators whenenergized by an electrical current. Further to the above, the clutches6110, 6210, and/or 6310 can be retained in their engaged positions bythe drive rings 6120, 6220, and/or 6320, respectively. Morespecifically, in at least one instance, the drive rings 6120, 6220,and/or 6320 are comprised of an elastic material which grips orfrictionally holds the clutches 6110, 6210, and/or 6310, respectively,in their engaged positions. In various alternative embodiments, theclutch system 6000 comprises a first biasing member, such as a spring,for example, configured to bias the first clutch 6110 into its engagedposition, a second biasing member, such as a spring, for example,configured to bias the second clutch 6210 into its engaged position,and/or a third biasing member, such as a spring, for example, configuredto bias the third clutch 6110 into its engaged position. In sucharrangements, the biasing forces of the springs can be overcome by theelectromagnetic forces applied by the electromagnetic actuators 6140,6240, and/or 6340, respectively, as needed to selectively hold theclutches 6110, 6210, and 6310 in their disengaged positions. In any oneoperational mode of the surgical system, the control assembly 1800 canenergize one of the electromagnetic actuators to engage one of theclutches while energizing the other two electromagnetic actuators todisengage the other two clutches.

Although the clutch system 6000 comprises three clutches to controlthree drive systems of the surgical system, a clutch system can compriseany suitable number of clutches to control any suitable number ofsystems. Moreover, although the clutches of the clutch system 6000 slideproximally and distally between their engaged and disengaged positions,the clutches of a clutch system can move in any suitable manner. Inaddition, although the clutches of the clutch system 6000 are engagedone at a time to control one drive motion at a time, various instancesare envisioned in which more than one clutch can be engaged to controlmore than one drive motion at a time.

In view of the above, the reader should appreciate that the controlsystem 1800 is configured to, one, operate the motor system 1600 torotate the drive shaft system 2700 in an appropriate direction and, two,operate the clutch system 6000 to transfer the rotation of the driveshaft system 2700 to the appropriate function of the end effector 7000.Moreover, as discussed above, the control system 1800 is responsive toinputs from the clamping trigger system 2600 of the shaft assembly 2000and the input system 1400 of the handle 1000. When the clamping triggersystem 2600 is actuated, as discussed above, the control system 1800activates the first clutch assembly 6100 and deactivates the secondclutch assembly 6200 and the third clutch assembly 6300. In suchinstances, the control system 1800 also supplies power to the motorsystem 1600 to rotate the drive shaft system 2700 in a first directionto clamp the jaw assembly 7100 of the end effector 7000. When thecontrol system 1800 detects that the jaw assembly 7100 is in its clampedconfiguration, the control system 1800 stops the motor assembly 1600 anddeactivates the first clutch assembly 6100. When the control system 1800detects that the clamping trigger system 2600 has been moved to, or isbeing moved to, its unactuated position, the control system 1800activates, or maintains the activation of, the first clutch assembly6100 and deactivates, or maintains the deactivation of, the secondclutch assembly 6200 and the third clutch assembly 6300. In suchinstances, the control system 1800 also supplies power to the motorsystem 1600 to rotate the drive shaft system 2700 in a second directionto open the jaw assembly 7100 of the end effector 7000.

When the rotation actuator 1420 is actuated in a first direction,further to the above, the control system 1800 activates the secondclutch assembly 6200 and deactivates the first clutch assembly 6100 andthe third clutch assembly 6300. In such instances, the control system1800 also supplies power to the motor system 1600 to rotate the driveshaft system 2700 in a first direction to rotate the end effector 7000in a first direction. When the control system 1800 detects that therotation actuator 1420 has been actuated in a second direction, thecontrol system 1800 activates, or maintains the activation of, thesecond clutch assembly 6200 and deactivates, or maintains thedeactivation of, the first clutch assembly 6100 and the third clutchassembly 6300. In such instances, the control system 1800 also suppliespower to the motor system 1600 to rotate the drive shaft system 2700 ina second direction to rotate the drive shaft system 2700 in a seconddirection to rotate the end effector 7000 in a second direction. Whenthe control system 1800 detects that the rotation actuator 1420 is notactuated, the control system 1800 deactivates the second clutch assembly6200.

When the first articulation actuator 1432 is depressed, further to theabove, the control system 1800 activates the third clutch assembly 6300and deactivates the first clutch assembly 6100 and the second clutchassembly 6200. In such instances, the control system 1800 also suppliespower to the motor system 1600 to rotate the drive shaft system 2700 ina first direction to articulate the end effector 7000 in a firstdirection. When the control system 1800 detects that the secondarticulation actuator 1434 is depressed, the control system 1800activates, or maintains the activation of, the third clutch assembly6200 and deactivates, or maintains the deactivation of, the first clutchassembly 6100 and the second clutch assembly 6200. In such instances,the control system 1800 also supplies power to the motor system 1600 torotate the drive shaft system 2700 in a second direction to articulatethe end effector 7000 in a second direction. When the control system1800 detects that neither the first articulation actuator 1432 nor thesecond articulation actuator 1434 are actuated, the control system 1800deactivates the third clutch assembly 6200.

Further to the above, the control system 1800 is configured to changethe operating mode of the stapling system based on the inputs itreceives from the clamping trigger system 2600 of the shaft assembly2000 and the input system 1400 of the handle 1000. The control system1800 is configured to shift the clutch system 6000 before rotating theshaft drive system 2700 to perform the corresponding end effectorfunction. Moreover, the control system 1800 is configured to stop therotation of the shaft drive system 2700 before shifting the clutchsystem 6000. Such an arrangement can prevent the sudden movements in theend effector 7000. Alternatively, the control system 1800 can shift theclutch system 600 while the shaft drive system 2700 is rotating. Such anarrangement can allow the control system 1800 to shift quickly betweenoperating modes.

As discussed above, referring to FIG. 34, the distal attachment portion2400 of the shaft assembly 2000 comprises an end effector lock 6400configured to prevent the end effector 7000 from being unintentionallydecoupled from the shaft assembly 2000. The end effector lock 6400comprises a lock end 6410 selectively engageable with the annular arrayof lock notches 7410 defined on the proximal attachment portion 7400 ofthe end effector 7000, a proximal end 6420, and a pivot 6430 rotatablyconnecting the end effector lock 6400 to the articulation link 2320.When the third clutch 6310 of the third clutch assembly 6300 is in itsdisengaged position, as illustrated in FIG. 34, the third clutch 6310 iscontact with the proximal end 6420 of the end effector lock 6400 suchthat the lock end 6410 of the end effector lock 6400 is engaged with thearray of lock notches 7410. In such instances, the end effector 7000 canrotate relative to the end effector lock 6400 but cannot translaterelative to the distal attachment portion 2400. When the third clutch6310 is moved into its engaged position, as illustrated in FIG. 35, thethird clutch 6310 is no longer engaged with the proximal end 6420 of theend effector lock 6400. In such instances, the end effector lock 6400 isfree to pivot upwardly and permit the end effector 7000 to be detachedfrom the shaft assembly 2000.

The above being said, referring again to FIG. 34, it is possible thatthe second clutch 6210 of the second clutch assembly 6200 is in itsdisengaged position when the clinician detaches, or attempts to detach,the end effector 7000 from the shaft assembly 2000. As discussed above,the second clutch 6210 is engaged with the second clutch lock 6250 whenthe second clutch 6210 is in its disengaged position and, in suchinstances, the second clutch lock 6250 is pushed into engagement withthe articulation link 2340. More specifically, the second clutch lock6250 is positioned in the channel 2345 defined in the articulation 2340when the second clutch 6210 is engaged with the second clutch lock 6250which may prevent, or at least impede, the end effector 7000 from beingdetached from the shaft assembly 2000. To facilitate the release of theend effector 7000 from the shaft assembly 2000, the control system 1800can move the second clutch 6210 into its engaged position in addition tomoving the third clutch 6310 into its engaged position. In suchinstances, the end effector 7000 can clear both the end effector lock6400 and the second clutch lock 6250 when the end effector 7000 isremoved.

In at least one instance, further to the above, the drive module 1100comprises an input switch and/or sensor in communication with thecontrol system 1800 via the input system 1400, and/or the control system1800 directly, which, when actuated, causes the control system 1800 tounlock the end effector 7000. In various instances, the drive module1100 comprises an input screen 1440 in communication with the board 1410of the input system 1400 which is configured to receive an unlock inputfrom the clinician. In response to the unlock input, the control system1800 can stop the motor system 1600, if it is running, and unlock theend effector 7000 as described above. The input screen 1440 is alsoconfigured to receive a lock input from the clinician in which the inputsystem 1800 moves the second clutch assembly 6200 and/or the thirdclutch assembly 6300 into their unactuated states to lock the endeffector 7000 to the shaft assembly 2000.

FIG. 37 depicts a shaft assembly 2000′ in accordance with at least onealternative embodiment. The shaft assembly 2000′ is similar to the shaftassembly 2000 in many respects, most of which will not be repeatedherein for the sake of brevity. Similar to the shaft assembly 2000, theshaft assembly 2000′ comprises a shaft frame, i.e., shaft frame 2530′.The shaft frame 2530′ comprises a longitudinal passage 2535′ and, inaddition, a plurality of clutch position sensors, i.e., a first sensor6180′, a second sensor 6280′, and a third sensor 6380′ positioned in theshaft frame 2530′. The first sensor 6180′ is in signal communicationwith the control system 1800 as part of a first sensing circuit. Thefirst sensing circuit comprises signal wires extending through thelongitudinal passage 2535′; however, the first sensing circuit cancomprise a wireless signal transmitter and receiver to place the firstsensor 6180′ in signal communication with the control system 1800. Thefirst sensor 6180′ is positioned and arranged to detect the position ofthe first clutch 6110 of the first clutch assembly 6100. Based on datareceived from the first sensor 6180′, the control system 1800 candetermine whether the first clutch 6110 is in its engaged position, itsdisengaged position, or somewhere in-between. With this information, thecontrol system 1800 can assess whether or not the first clutch 6110 isin the correct position given the operating state of the surgicalinstrument. For instance, if the surgical instrument is in its jawclamping/opening operating state, the control system 1800 can verifywhether the first clutch 6110 is properly positioned in its engagedposition. In such instances, further to the below, the control system1800 can also verify that the second clutch 6210 is in its disengagedposition via the second sensor 6280′ and that the third clutch 6310 isin its disengaged position via the third sensor 6380′. Correspondingly,the control system 1800 can verify whether the first clutch 6110 isproperly positioned in its disengaged position if the surgicalinstrument is not in its jaw clamping/opening state. To the extent thatthe first clutch 6110 is not in its proper position, the control system1800 can actuate the first electromagnetic actuator 6140 in an attemptto properly position the first clutch 6110. Likewise, the control system1800 can actuate the electromagnetic actuators 6240 and/or 6340 toproperly position the clutches 6210 and/or 6310, if necessary.

The second sensor 6280′ is in signal communication with the controlsystem 1800 as part of a second sensing circuit. The second sensingcircuit comprises signal wires extending through the longitudinalpassage 2535′; however, the second sensing circuit can comprise awireless signal transmitter and receiver to place the second sensor6280′ in signal communication with the control system 1800. The secondsensor 6280′ is positioned and arranged to detect the position of thesecond clutch 6210 of the first clutch assembly 6200. Based on datareceived from the second sensor 6280′, the control system 1800 candetermine whether the second clutch 6210 is in its engaged position, itsdisengaged position, or somewhere in-between. With this information, thecontrol system 1800 can assess whether or not the second clutch 6210 isin the correct position given the operating state of the surgicalinstrument. For instance, if the surgical instrument is in its endeffector rotation operating state, the control system 1800 can verifywhether the second clutch 6210 is properly positioned in its engagedposition. In such instances, the control system 1800 can also verifythat the first clutch 6110 is in its disengaged position via the firstsensor 6180′ and, further to the below, the control system 1800 can alsoverify that the third clutch 6310 is in its disengaged position via thethird sensor 6380′. Correspondingly, the control system 1800 can verifywhether the second clutch 6110 is properly positioned in its disengagedposition if the surgical instrument is not in its end effector rotationstate. To the extent that the second clutch 6210 is not in its properposition, the control system 1800 can actuate the second electromagneticactuator 6240 in an attempt to properly position the second clutch 6210.Likewise, the control system 1800 can actuate the electromagneticactuators 6140 and/or 6340 to properly position the clutches 6110 and/or6310, if necessary.

The third sensor 6380′ is in signal communication with the controlsystem 1800 as part of a third sensing circuit. The third sensingcircuit comprises signal wires extending through the longitudinalpassage 2535′; however, the third sensing circuit can comprise awireless signal transmitter and receiver to place the third sensor 6380′in signal communication with the control system 1800. The third sensor6380′ is positioned and arranged to detect the position of the thirdclutch 6310 of the third clutch assembly 6300. Based on data receivedfrom the third sensor 6380′, the control system 1800 can determinewhether the third clutch 6310 is in its engaged position, its disengagedposition, or somewhere in-between. With this information, the controlsystem 1800 can assess whether or not the third clutch 6310 is in thecorrect position given the operating state of the surgical instrument.For instance, if the surgical instrument is in its end effectorarticulation operating state, the control system 1800 can verify whetherthe third clutch 6310 is properly positioned in its engaged position. Insuch instances, the control system 1800 can also verify that the firstclutch 6110 is in its disengaged position via the first sensor 6180′ andthat the second clutch 6210 is in its disengaged position via the secondsensor 6280′. Correspondingly, the control system 1800 can verifywhether the third clutch 6310 is properly positioned in its disengagedposition if the surgical instrument is not in its end effectorarticulation state. To the extent that the third clutch 6310 is not inits proper position, the control system 1800 can actuate the thirdelectromagnetic actuator 6340 in an attempt to properly position thethird clutch 6310. Likewise, the control system 1800 can actuate theelectromagnetic actuators 6140 and/or 6240 to properly position theclutches 6110 and/or 6210, if necessary.

Further to the above, the clutch position sensors, i.e., the firstsensor 6180′, the second sensor 6280′, and the third sensor 6380′ cancomprise any suitable type of sensor. In various instances, the firstsensor 6180′, the second sensor 6280′, and the third sensor 6380′ eachcomprise a proximity sensor. In such an arrangement, the sensors 6180′,6280′, and 6380′ are configured to detect whether or not the clutches6110, 6210, and 6310, respectively, are in their engaged positions. Invarious instances, the first sensor 6180′, the second sensor 6280′, andthe third sensor 6380′ each comprise a Hall Effect sensor, for example.In such an arrangement, the sensors 6180′, 6280′, and 6380′ can not onlydetect whether or not the clutches 6110, 6210, and 6310, respectively,are in their engaged positions but the sensors 6180′, 6280′, and 6380′can also detect how close the clutches 6110, 6210, and 6310 are withrespect to their engaged or disengaged positions.

FIG. 38 depicts the shaft assembly 2000′ and an end effector 7000″ inaccordance with at least one alternative embodiment. The end effector7000″ is similar to the end effector 7000 in many respects, most ofwhich will not be repeated herein for the sake of brevity. Similar tothe end effector 7000, the shaft assembly 7000″ comprises a jaw assembly7100 and a jaw assembly drive configured to move the jaw assembly 7100between its open and closed configurations. The jaw assembly drivecomprises drive links 7140, a drive nut 7150″, and a drive screw 6130″.The drive nut 7150″ comprises a sensor 7190″ positioned therein which isconfigured to detect the position of a magnetic element 6190″ positionedin the drive screw 6130″. The magnetic element 6190″ is positioned in anelongate aperture 6134″ defined in the drive screw 6130″ and cancomprise a permanent magnet and/or can be comprised of iron, nickel,and/or any suitable metal, for example. In various instances, the sensor7190″ comprises a proximity sensor, for example, which is in signalcommunication with the control system 1800. In certain instances, thesensor 7190″ comprises a Hall Effect sensor, for example, in signalcommunication with the control system 1800. In certain instances, thesensor 7190″ comprises an optical sensor, for example, and thedetectable element 6190″ comprises an optically detectable element, suchas a reflective element, for example. In either event, the sensor 7190″is configured to communicate wirelessly with the control system 1800 viaa wireless signal transmitter and receiver and/or via a wired connectionextending through the shaft frame passage 2532′, for example.

The sensor 7190″, further to the above, is configured to detect when themagnetic element 6190″ is adjacent to the sensor 7190″ such that thecontrol system 1800 can use this data to determine that the jaw assembly7100 has reached the end of its clamping stroke. At such point, thecontrol system 1800 can stop the motor assembly 1600. The sensor 7190″and the control system 1800 are also configured to determine thedistance between where the drive screw 6130″ is currently positioned andwhere the drive screw 6130″ should be positioned at the end of itsclosure stroke in order to calculate the amount of closure stroke of thedrive screw 6130″ that is still needed to close the jaw assembly 7100.Moreover, such information can be used by the control system 1800 toassess the current configuration of the jaw assembly 7100, i.e., whetherthe jaw assembly 7100 is in its open configuration, its closedconfiguration, or a partially closed configuration. The sensor systemcould be used to determine when the jaw assembly 7100 has reached itsfully open position and stop the motor assembly 1600 at that point. Invarious instances, the control system 1800 could use this sensor systemto confirm that the first clutch assembly 6100 is in its actuated stateby confirming that the jaw assembly 7100 is moving while the motorassembly 1600 is turning. Similarly, the control system 1800 could usethis sensor system to confirm that the first clutch assembly 6100 is inits unactuated state by confirming that the jaw assembly 7100 is notmoving while the motor assembly 1600 is turning.

FIG. 39 depicts a shaft assembly 2000′″ and an end effector 7000′″ inaccordance with at least one alternative embodiment. The shaft assembly2000′″ is similar to the shaft assemblies 2000 and 2000′ in manyrespects, most of which will not be repeated herein for the sake ofbrevity. The end effector 7000′″ is similar to the end effectors 7000and 7000″ in many respects, most of which will not be repeated hereinfor the sake of brevity. Similar to the end effector 7000, the endeffector 7000′″ comprises a jaw assembly 7100 and a jaw assembly driveconfigured to move the jaw assembly 7100 between its open and closedconfigurations and, in addition, an end effector rotation drive thatrotates the end effector 7000′″ relative to the distal attachmentportion 2400 of the shaft assembly 2000′. The end effector rotationdrive comprises an outer housing 6230′″ that is rotated relative to ashaft frame 2530′″ of the end effector 7000′″ by the second clutchassembly 6200. The shaft frame 2530′″ comprises a sensor 6290′″positioned therein which is configured to detect the position of amagnetic element 6190′″ positioned in and/or on the outer housing6230′″. The magnetic element 6190′″ can comprise a permanent magnetand/or can be comprised of iron, nickel, and/or any suitable metal, forexample. In various instances, the sensor 6290′″ comprises a proximitysensor, for example, in signal communication with the control system1800. In certain instances, the sensor 6290′″ comprises a Hall Effectsensor, for example, in signal communication with the control system1800. In either event, the sensor 6290′″ is configured to communicatewirelessly with the control system 1800 via a wireless signaltransmitter and receiver and/or via a wired connection extending throughthe shaft frame passage 2532′, for example. In various instances, thecontrol system 1800 can use the sensor 6290′″ to confirm whether themagnetic element 6190′″ is rotating and, thus, confirm that the secondclutch assembly 6200 is in its actuated state. Similarly, the controlsystem 1800 can use the sensor 6290′″ to confirm whether the magneticelement 6190′″ is not rotating and, thus, confirm that the second clutchassembly 6200 is in its unactuated state. The control system 1800 canalso use the sensor 6290′″ to confirm that the second clutch assembly6200 is in its unactuated state by confirming that the second clutch6210 is positioned adjacent the sensor 6290′″.

FIG. 40 depicts a shaft assembly 2000″″ in accordance with at least onealternative embodiment. The shaft assembly 2000″″ is similar to theshaft assemblies 2000, 2000′, and 2000′″ in many respects, most of whichwill not be repeated herein for the sake of brevity. Similar to theshaft assembly 2000, the shaft assembly 2000″″ comprises, among otherthings, an elongate shaft 2200, an articulation joint 2300, and a distalattachment portion 2400 configured to receive an end effector, such asend effector 7000′, for example. Similar to the shaft assembly 2000, theshaft assembly 2000″″ comprises an articulation drive, i.e.,articulation drive 6330″″ configured to rotate the distal attachmentportion 2400 and the end effector 7000′ about the articulation joint2300. Similar to the above, a shaft frame 2530″″ comprises a sensorpositioned therein configured to detect the position, and/or rotation,of a magnetic element 6390″″ positioned in and/or on the articulationdrive 6330″″. The magnetic element 6390″″ can comprise a permanentmagnet and/or can be comprised of iron, nickel, and/or any suitablemetal, for example. In various instances, the sensor comprises aproximity sensor, for example, in signal communication with the controlsystem 1800. In certain instances, the sensor comprises a Hall Effectsensor, for example, in signal communication with the control system1800. In either event, the sensor is configured to communicatewirelessly with the control system 1800 via a wireless signaltransmitter and receiver and/or via a wired connection extending throughthe shaft frame passage 2532′, for example. In various instances, thecontrol system 1800 can use the sensor to confirm whether the magneticelement 6390″″ is rotating and, thus, confirm that the third clutchassembly 6300 is in its actuated state. Similarly, the control system1800 can use the sensor to confirm whether the magnetic element 6390″″is not rotating and, thus, confirm that the third clutch assembly 6300is in its unactuated state. In certain instances, the control system1800 can use the sensor to confirm that the third clutch assembly 6300is in its unactuated state by confirming that the third clutch 6310 ispositioned adjacent the sensor.

Referring to FIG. 40 once again, the shaft assembly 2000″″ comprises anend effector lock 6400′ configured to releasably lock the end effector7000′, for example, to the shaft assembly 2000″″. The end effector lock6400′ is similar to the end effector lock 6400 in many respects, most ofwhich will not be discussed herein for the sake of brevity. Notably,though, a proximal end 6420′ of the lock 6400′ comprises a tooth 6422′configured to engage the annular slot 6312 of the third clutch 6310 andreleasably hold the third clutch 6310 in its disengaged position. Thatsaid, the actuation of the third electromagnetic assembly 6340 candisengage the third clutch 6310 from the end effector lock 6400′.Moreover, in such instances, the proximal movement of the third clutch6310 into its engaged position rotates the end effector lock 6400′ intoa locked position and into engagement with the lock notches 7410 to lockthe end effector 7000′ to the shaft assembly 2000″″. Correspondingly,the distal movement of the third clutch 6310 into its disengagedposition unlocks the end effector 7000′ and allows the end effector7000′ to be disassembled from the shaft assembly 2000″″.

Further to the above, an instrument system including a handle and ashaft assembly attached thereto can be configured to perform adiagnostic check to assess the state of the clutch assemblies 6100,6200, and 6300. In at least one instance, the control system 1800sequentially actuates the electromagnetic actuators 6140, 6240, and/or6340—in any suitable order—to verify the positions of the clutches 6110,6210, and/or 6310, respectively, and/or verify that the clutches areresponsive to the electromagnetic actuators and, thus, not stuck. Thecontrol system 1800 can use sensors, including any of the sensorsdisclosed herein, to verify the movement of the clutches 6110, 6120, and6130 in response to the electromagnetic fields created by theelectromagnetic actuators 6140, 6240, and/or 6340. In addition, thediagnostic check can also include verifying the motions of the drivesystems. In at least one instance, the control system 1800 sequentiallyactuates the electromagnetic actuators 6140, 6240, and/or 6340—in anysuitable order—to verify that the jaw drive opens and/or closes the jawassembly 7100, the rotation drive rotates the end effector 7000, and/orthe articulation drive articulates the end effector 7000, for example.The control system 1800 can use sensors to verify the motions of the jawassembly 7100 and end effector 7000.

The control system 1800 can perform the diagnostic test at any suitabletime, such as when a shaft assembly is attached to the handle and/orwhen the handle is powered on, for example. If the control system 1800determines that the instrument system passed the diagnostic test, thecontrol system 1800 can permit the ordinary operation of the instrumentsystem. In at least one instance, the handle can comprise an indicator,such as a green LED, for example, which indicates that the diagnosticcheck has been passed. If the control system 1800 determines that theinstrument system failed the diagnostic test, the control system 1800can prevent and/or modify the operation of the instrument system. In atleast one instance, the control system 1800 can limit the functionalityof the instrument system to only the functions necessary to remove theinstrument system from the patient, such as straightening the endeffector 7000 and/or opening and closing the jaw assembly 7100, forexample. In at least one respect, the control system 1800 enters into alimp mode. The limp mode of the control system 1800 can reduce a currentrotational speed of the motor 1610 by any percentage selected from arange of about 75% to about 25%, for example. In one example, the limpmode reduces a current rotational speed of the motor 1610 by 50%. In oneexample, the limp mode reduces the current rotational speed of the motor1610 by 75%. The limp mode may cause a current torque of the motor 1610to be reduced by any percentage selected from a range of about 75% toabout 25%, for example. In one example, the limp mode reduces a currenttorque of the motor 1610 by 50%. The handle can comprise an indicator,such as a red LED, for example, which indicates that the instrumentsystem failed the diagnostic check and/or that the instrument system hasentered into a limp mode. The above being said, any suitable feedbackcan be used to warn the clinician that the instrument system is notoperating properly such as, for example, an audible warning and/or atactile or vibratory warning, for example.

FIGS. 41-43 depict a clutch system 6000′ in accordance with at least onealternative embodiment. The clutch system 6000′ is similar to the clutchsystem 6000 in many respects, most of which will not be repeated hereinfor the sake of brevity. Similar to the clutch system 6000, the clutchsystem 6000′ comprises a clutch assembly 6100′ which is actuatable toselectively couple a rotatable drive input 6030′ with a rotatable driveoutput 6130′. The clutch assembly 6100′ comprises clutch plates 6110′and drive rings 6120′. The clutch plates 6110′ are comprised of amagnetic material, such as iron and/or nickel, for example, and cancomprise a permanent magnet. As described in greater detail below, theclutch plates 6110′ are movable between unactuated positions (FIG. 42)and actuated positions (FIG. 43) within the drive output 6130′. Theclutch plates 6110′ are slideably positioned in apertures defined in thedrive output 6130′ such that the clutch plates 6110′ rotate with thedrive output 6130′ regardless of whether the clutch plates 6110′ are intheir unactuated or actuated positions.

When the clutch plates 6110′ are in their unactuated positions, asillustrated in FIG. 42, the rotation of the drive input 6030′ is nottransferred to the drive output 6130′. More specifically, when the driveinput 6030′ is rotated, in such instances, the drive input 6030′ slidespast and rotates relative to the drive rings 6120′ and, as a result, thedrive rings 6120′ do not drive the clutch plates 6110′ and the driveoutput 6130′. When the clutch plates 6110′ are in their actuatedpositions, as illustrated in FIG. 43, the clutch plates 6110′resiliently compress the drive rings 6120′ against the drive input6030′. The drive rings 6120′ are comprised of any suitable compressiblematerial, such as rubber, for example. In any event, in such instances,the rotation of the drive input 6030′ is transferred to the drive output6130′ via the drive rings 6120′ and the clutch plates 6110′. The clutchsystem 6000′ comprises a clutch actuator 6140′ configured to move theclutch plates 6110′ into their actuated positions. The clutch actuator6140′ is comprised of a magnetic material such as iron and/or nickel,for example, and can comprise a permanent magnet. The clutch actuator6140′ is slideably positioned in a longitudinal shaft frame 6050′extending through the drive input 6030′ and can be moved between anunactuated position (FIG. 42) and an actuated position (FIG. 43) by aclutch shaft 6060′. In at least one instance, the clutch shaft 6060′comprises a polymer cable, for example. When the clutch actuator 6140′is in its actuated position, as illustrated in FIG. 43, the clutchactuator 6140′ pulls the clutch plates 6110′ inwardly to compress thedrive rings 6120′, as discussed above. When the clutch actuator 6140′ ismoved into its unactuated position, as illustrated in FIG. 42, the driverings 6120′ resiliently expand and push the clutch plates 6110′ awayfrom the drive input 6030′. In various alternative embodiments, theclutch actuator 6140′ can comprise an electromagnet. In such anarrangement, the clutch actuator 6140′ can be actuated by an electricalcircuit extending through a longitudinal aperture defined in the clutchshaft 6060′, for example. In various instances, the clutch system 6000′further comprises electrical wires 6040′, for example, extending throughthe longitudinal aperture.

FIG. 44 depicts an end effector 7000 a including a jaw assembly 7100 a,a jaw assembly drive, and a clutch system 6000 a in accordance with atleast one alternative embodiment. The jaw assembly 7100 a comprises afirst jaw 7110 a and a second jaw 7120 a which are selectively rotatableabout a pivot 7130 a. The jaw assembly drive comprises a translatableactuator rod 7160 a and drive links 7140 a which are pivotably coupledto the actuator rod 7160 a about a pivot 7150 a. The drive links 7140 aare also pivotably coupled to the jaws 7110 a and 7120 a such that thejaws 7110 a and 7120 a are rotated closed when the actuator rod 7160 ais pulled proximally and rotated open when the actuator rod 7160 a ispushed distally. The clutch system 6000 a is similar to the clutchsystems 6000 and 6000′ in many respects, most of which will not berepeated herein for the sake of brevity. The clutch system 6000 acomprises a first clutch assembly 6100 a and a second clutch assembly6200 a which are configured to selectively transmit the rotation of adrive input 6030 a to rotate the jaw assembly 7100 a about alongitudinal axis and articulate the jaw assembly 7100 a about anarticulation joint 7300 a, respectively, as described in greater detailbelow.

The first clutch assembly 6100 a comprises clutch plates 6110 a anddrive rings 6120 a and work in a manner similar to the clutch plates6110′ and drive rings 6120′ discussed above. When the clutch pates 6110a are actuated by an electromagnetic actuator 6140 a, the rotation ofthe drive input 6030 a is transferred to an outer shaft housing 7200 a.More specifically, the outer shaft housing 7200 a comprises a proximalouter housing 7210 a and a distal outer housing 7220 a which isrotatably supported by the proximal outer housing 7210 a and is rotatedrelative to the proximal outer housing 7210 a by the drive input 6030 awhen the clutch plates 6110 a are in their actuated position. Therotation of the distal outer housing 7220 a rotates the jaw assembly7100 a about the longitudinal axis owing to fact that the pivot 7130 aof the jaw assembly 7100 a is mounted to the distal outer housing 7220a. As a result, the outer shaft housing 7200 a rotates the jaw assembly7100 a in a first direction when the outer shaft housing 7200 a isrotated in a first direction by the drive input 6030 a. Similarly, theouter shaft housing 7200 a rotates the jaw assembly 7100 a in a seconddirection when the outer shaft housing 7200 a is rotated in a seconddirection by the drive input 6030 a. When the electromagnetic actuator6140 a is de-energized, the drive rings 6120 a expand and the clutchplates 6110 a are moved into their unactuated positions, therebydecoupling the end effector rotation drive from the drive input 6030 a.

The second clutch assembly 6200 a comprises clutch plates 6210 a anddrive rings 6220 a and work in a manner similar to the clutch plates6110′ and drive rings 6120′ discussed above. When the clutch pates 6210a are actuated by an electromagnetic actuator 6240 a, the rotation ofthe drive input 6030 a is transferred to an articulation drive 6230 a.The articulation drive 6230 a is rotatably supported within an outershaft housing 7410 a of an end effector attachment portion 7400 a and isrotatably supported by a shaft frame 6050 a extending through the outershaft housing 7410 a. The articulation drive 6230 a comprises a gearface defined thereon which is operably intermeshed with a stationarygear face 7230 a defined on the proximal outer housing 7210 a of theouter shaft housing 7200 a. As a result, the articulation drive 6230 aarticulates the outer shaft housing 7200 a and the jaw assembly 7100 ain a first direction when the articulation drive 6230 a is rotated in afirst direction by the drive input 6030 a. Similarly, the articulationdrive 6230 a articulates the outer shaft housing 7200 a and the jawassembly 7100 a in a second direction when the articulation drive 6230 ais rotated in a second direction by the drive input 6030 a. When theelectromagnetic actuator 6240 a is de-energized, the drive rings 6220 aexpand and the clutch plates 6210 a are moved into their unactuatedpositions, thereby decoupling the end effector articulation drive fromthe drive input 6030 a.

Further to the above, the shaft assembly 4000 is illustrated in FIGS.45-49. The shaft assembly 4000 is similar to the shaft assemblies 2000,2000′, 2000″′, and 2000″″ in many respects, most of which will not berepeated herein for the sake of brevity. The shaft assembly 4000comprises a proximal portion 4100, an elongate shaft 4200, a distalattachment portion 2400, and an articulate joint 2300 which rotatablyconnects the distal attachment portion 2040 to the elongate shaft 4200.The proximal portion 4100, similar to the proximal portion 2100, isoperably attachable to the drive module 1100 of the handle 1000. Theproximal portion 4100 comprises a housing 4110 including an attachmentinterface 4130 configured to mount the shaft assembly 4000 to theattachment interface 1130 of the handle 1000. The shaft assembly 4000further comprises a frame 4500 including a shaft 4510 configured to becoupled to the shaft 1510 of the handle frame 1500 when the shaftassembly 4000 is attached to the handle 1000. The shaft assembly 4000also comprises a drive system 4700 including a rotatable drive shaft4710 configured to be operably coupled to the drive shaft 1710 of thehandle drive system 1700 when the shaft assembly 4000 is attached to thehandle 1000. The distal attachment portion 2400 is configured to receivean end effector, such as end effector 8000, for example. The endeffector 8000 is similar to the end effector 7000 in many respects, mostof which will not be repeated herein for the sake of brevity. That said,the end effector 8000 comprises a jaw assembly 8100 configured to, amongother things, grasp tissue.

As discussed above, referring primarily to FIGS. 47-49, the frame 4500of the shaft assembly 4000 comprises a frame shaft 4510. The frame shaft4510 comprises a notch, or cut-out, 4530 defined therein. As discussedin greater detail below, the cut-out 4530 is configured to provideclearance for a jaw closure actuation system 4600. The frame 4500further comprises a distal portion 4550 and a bridge 4540 connecting thedistal portion 4550 to the frame shaft 4510. The frame 4500 furthercomprises a longitudinal portion 4560 extending through the elongateshaft 4200 to the distal attachment portion 2400. Similar to the above,the frame shaft 4510 comprises one or more electrical traces definedthereon and/or therein. The electrical traces extend through thelongitudinal portion 4560, the distal portion 4550, the bridge 4540,and/or any suitable portion of the frame shaft 4510 to the electricalcontacts 2520. Referring primarily to FIG. 48, the distal portion 4550and longitudinal portion 4560 comprise a longitudinal aperture definedtherein which is configured to receive a rod 4660 of the jaw closureactuation system 4600, as described in greater detail below.

As also discussed above, referring primarily to FIGS. 48 and 49, thedrive system 4700 of the shaft assembly 4000 comprises a drive shaft4710. The drive shaft 4710 is rotatably supported within the proximalshaft housing 4110 by the frame shaft 4510 and is rotatable about alongitudinal axis extending through the frame shaft 4510. The drivesystem 4700 further comprises a transfer shaft 4750 and an output shaft4780. The transfer shaft 4750 is also rotatably supported within theproximal shaft housing 4110 and is rotatable about a longitudinal axisextending parallel to, or at least substantially parallel to, the frameshaft 4510 and the longitudinal axis defined therethrough. The transfershaft 4750 comprises a proximal spur gear 4740 fixedly mounted theretosuch that the proximal spur gear 4740 rotates with the transfer shaft4750. The proximal spur gear 4740 is operably intermeshed with anannular gear face 4730 defined around the outer circumference of thedrive shaft 4710 such that the rotation of the drive shaft 4710 istransferred to the transfer shaft 4750. The transfer shaft 4750 furthercomprises a distal spur gear 4760 fixedly mounted thereto such that thedistal spur gear 4760 rotates with the transfer shaft 4750. The distalspur gear 4760 is operably intermeshed with an annular gear 4770 definedaround the outer circumference of the output shaft 4780 such that therotation of the transfer shaft 4750 is transferred to the output shaft4780. Similar to the above, the output shaft 4780 is rotatably supportedwithin the proximal shaft housing 4110 by the distal portion 4550 of theshaft frame 4500 such that the output shaft 4780 rotates about thelongitudinal shaft axis. Notably, the output shaft 4780 is not directlycoupled to the input shaft 4710; rather, the output shaft 4780 isoperably coupled to the input shaft 4710 by the transfer shaft 4750.Such an arrangement provides room for the manually-actuated jaw closureactuation system 4600 discussed below.

Further to the above, referring primarily to FIGS. 47 and 48, the jawclosure actuation system 4600 comprises an actuation, or scissors,trigger 4610 rotatably coupled to the proximal shaft housing 4110 abouta pivot 4620. The actuation trigger 4610 comprises an elongate portion4612, a proximal end 4614, and a grip ring aperture 4616 defined in theproximal end 4614 which is configured to be gripped by the clinician.The shaft assembly 4000 further comprises a stationary grip 4160extending from the proximal housing 4110. The stationary grip 4160comprises an elongate portion 4162, a proximal end 4164, and a grip ringaperture 4166 defined in the proximal end 4164 which is configured to begripped by the clinician. In use, as described in greater detail below,the actuation trigger 4610 is rotatable between an unactuated positionand an actuated position (FIG. 48), i.e., toward the stationary grip4160, to close the jaw assembly 8100 of the end effector 8000.

Referring primarily to FIG. 48, the jaw closure actuation system 4600further comprises a drive link 4640 rotatably coupled to the proximalshaft housing 4110 about a pivot 4650 and, in addition, an actuation rod4660 operably coupled to the drive link 4640. The actuation rod 4660extends through an aperture defined in the longitudinal frame portion4560 and is translatable along the longitudinal axis of the shaft frame4500. The actuation rod 4660 comprises a distal end operably coupled tothe jaw assembly 8100 and a proximal end 4665 positioned in a drive slot4645 defined in the drive link 4640 such that the actuation rod 4660 istranslated longitudinally when the drive link 4640 is rotated about thepivot 4650. Notably, the proximal end 4665 is rotatably supported withinthe drive slot 4645 such that the actuation rod 4660 can rotate with theend effector 8000.

Further to the above, the actuation trigger 4610 further comprises adrive arm 4615 configured to engage and rotate the drive link 4640proximally, and translate the actuation rod 4660 proximally, when theactuation trigger 4610 is actuated, i.e., moved closer to the proximalshaft housing 4110. In such instances, the proximal rotation of thedrive link 4640 resiliently compresses a biasing member, such as a coilspring 4670, for example, positioned intermediate the drive link 4640and the frame shaft 4510. When the actuation trigger 4610 is released,the compressed coil spring 4670 re-expands and pushes the drive link4640 and the actuation rod 4660 distally to open the jaw assembly 8100of the end effector 8000. Moreover, the distal rotation of the drivelink 4640 drives, and automatically rotates, the actuation trigger 4610back into its unactuated position. That being said, the clinician couldmanually return the actuation trigger 4610 back into its unactuatedposition. In such instances, the actuation trigger 4610 could be openedslowly. In either event, the shaft assembly 4000 further comprises alock configured to releasably hold the actuation trigger 4610 in itsactuated position such that the clinician can use their hand to performanother task without the jaw assembly 8100 opening unintentionally.

In various alternative embodiments, further to the above, the actuationrod 4660 can be pushed distally to close the jaw assembly 8100. In atleast one such instance, the actuation rod 4660 is mounted directly tothe actuation trigger 4610 such that, when the actuation trigger 4610 isactuated, the actuation trigger 4610 drives the actuation rod 4660distally. Similar to the above, the actuation trigger 4610 can compressa spring when the actuation trigger 4610 is closed such that, when theactuation trigger 4610 is released, the actuation rod 4660 is pushedproximally.

Further to the above, the shaft assembly 4000 has threefunctions—opening/closing the jaw assembly of an end effector, rotatingthe end effector about a longitudinal axis, and articulating the endeffector about an articulation axis. The end effector rotation andarticulation functions of the shaft assembly 4000 are driven by themotor assembly 1600 and the control system 1800 of the drive module 1100while the jaw actuation function is manually-driven by the jaw closureactuation system 4600. The jaw closure actuation system 4600 could be amotor-driven system but, instead, the jaw closure actuation system 4600has been kept a manually-driven system such that the clinician can havea better feel for the tissue being clamped within the end effector.While motorizing the end effector rotation and actuation systemsprovides certain advantages for controlling the position of the endeffector, motorizing the jaw closure actuation system 4600 may cause theclinician to lose a tactile sense of the force being applied to thetissue and may not be able to assess whether the force is insufficientor excessive. Thus, the jaw closure actuation system 4600 ismanually-driven even though the end effector rotation and articulationsystems are motor-driven.

FIG. 50 is a logic diagram of the control system 1800 of the surgicalsystem depicted in FIG. 1 in accordance with at least one embodiment.The control system 1800 comprises a control circuit. The control circuitincludes a microcontroller 1840 comprising a processor 1820 and a memory1830. One or more sensors, such as sensors 1880, 1890, 6180′, 6280′,6380′, 7190″, and/or 6290′″, for example, provide real time feedback tothe processor 1820. The control system 1800 further comprises a motordriver 1850 configured to control the electric motor 1610 and a trackingsystem 1860 configured to determine the position of one or morelongitudinally movable components in the surgical instrument, such asthe clutches 6110, 6120, and 6130 and/or the longitudinally-movabledrive nut 7150 of the jaw assembly drive, for example. The trackingsystem 1860 is also configured to determine the position of one or morerotational components in the surgical instrument, such as the driveshaft 2530, the outer shaft 6230, and/or the articulation drive 6330,for example. The tracking system 1860 provides position information tothe processor 1820, which can be programmed or configured to, amongother things, determine the position of the clutches 6110, 6120, and6130 and the drive nut 7150 as well as the orientation of the jaws 7110and 7120. The motor driver 1850 may be an A3941 available from AllegroMicrosystems, Inc., for example; however, other motor drivers may bereadily substituted for use in the tracking system 1860. A detaileddescription of an absolute positioning system is described in U.S.Patent Application Publication No. 2017/0296213, entitled SYSTEMS ANDMETHODS FOR CONTROLLING A SURGICAL STAPLING AND CUTTING INSTRUMENT, theentire disclosure of which is hereby incorporated herein by reference.

The microcontroller 1840 may be any single core or multicore processorsuch as those known under the trade name ARM Cortex by TexasInstruments, for example. In at least one instance, the microcontroller1840 is a LM4F230H5QR ARM Cortex-M4F Processor Core, available fromTexas Instruments, for example, comprising on-chip memory of 256 KBsingle-cycle flash memory, or other non-volatile memory, up to 40 MHz, aprefetch buffer to improve performance above 40 MHz, a 32 KBsingle-cycle serial random access memory (SRAM), internal read-onlymemory (ROM) loaded with StellarisWare® software, 2 KB electricallyerasable programmable read-only memory (EEPROM), one or more pulse widthmodulation (PWM) modules and/or frequency modulation (FM) modules, oneor more quadrature encoder inputs (QEI) analog, one or more 12-bitAnalog-to-Digital Converters (ADC) with 12 analog input channels, forexample, details of which are available from the product datasheet.

In various instances, the microcontroller 1840 comprises a safetycontroller comprising two controller-based families such as TMS570 andRM4x known under the trade name Hercules ARM Cortex R4, also by TexasInstruments. The safety controller may be configured specifically forIEC 61508 and ISO 26262 safety critical applications, among others, toprovide advanced integrated safety features while delivering scalableperformance, connectivity, and memory options.

The microcontroller 1840 is programmed to perform various functions suchas precisely controlling the speed and/or position of the drive nut 7150of the jaw closure assembly, for example. The microcontroller 1840 isalso programmed to precisely control the rotational speed and positionof the end effector 7000 and the articulation speed and position of theend effector 7000. In various instances, the microcontroller 1840computes a response in the software of the microcontroller 1840. Thecomputed response is compared to a measured response of the actualsystem to obtain an “observed” response, which is used for actualfeedback decisions. The observed response is a favorable, tuned, valuethat balances the smooth, continuous nature of the simulated responsewith the measured response, which can detect outside influences on thesystem.

The motor 1610 is controlled by the motor driver 1850. In various forms,the motor 1610 is a DC brushed driving motor having a maximum rotationalspeed of approximately 25,000 RPM, for example. In other arrangements,the motor 1610 includes a brushless motor, a cordless motor, asynchronous motor, a stepper motor, or any other suitable electricmotor. The motor driver 1850 may comprise an H-bridge driver comprisingfield-effect transistors (FETs), for example. The motor driver 1850 maybe an A3941 available from Allegro Microsystems, Inc., for example. TheA3941 driver 1850 is a full-bridge controller for use with externalN-channel power metal oxide semiconductor field effect transistors(MOSFETs) specifically designed for inductive loads, such as brush DCmotors. In various instances, the driver 1850 comprises a unique chargepump regulator provides full (>10 V) gate drive for battery voltagesdown to 7 V and allows the A3941 to operate with a reduced gate drive,down to 5.5 V. A bootstrap capacitor may be employed to provide theabove-battery supply voltage required for N-channel MOSFETs. An internalcharge pump for the high-side drive allows DC (100% duty cycle)operation. The full bridge can be driven in fast or slow decay modesusing diode or synchronous rectification. In the slow decay mode,current recirculation can be through the high-side or the lowside FETs.The power FETs are protected from shoot-through by resistor adjustabledead time. Integrated diagnostics provide indication of undervoltage,overtemperature, and power bridge faults, and can be configured toprotect the power MOSFETs under most short circuit conditions. Othermotor drivers may be readily substituted.

The tracking system 1860 comprises a controlled motor drive circuitarrangement comprising one or more position sensors, such as sensors1880, 1890, 6180′, 6280′, 6380′, 7190″, and/or 6290′″, for example. Theposition sensors for an absolute positioning system provide a uniqueposition signal corresponding to the location of a displacement member.As used herein, the term displacement member is used generically torefer to any movable member of the surgical system. In variousinstances, the displacement member may be coupled to any position sensorsuitable for measuring linear displacement. Linear displacement sensorsmay include contact or non-contact displacement sensors. Lineardisplacement sensors may comprise linear variable differentialtransformers (LVDT), differential variable reluctance transducers(DVRT), a slide potentiometer, a magnetic sensing system comprising amovable magnet and a series of linearly arranged Hall Effect sensors, amagnetic sensing system comprising a fixed magnet and a series ofmovable linearly arranged Hall Effect sensors, an optical sensing systemcomprising a movable light source and a series of linearly arrangedphoto diodes or photo detectors, or an optical sensing system comprisinga fixed light source and a series of movable linearly arranged photodiodes or photo detectors, or any combination thereof.

The position sensors 1880, 1890, 6180′, 6280′, 6380′, 7190″, and/or6290′″, for example, may comprise any number of magnetic sensingelements, such as, for example, magnetic sensors classified according towhether they measure the total magnetic field or the vector componentsof the magnetic field. The techniques used to produce both types ofmagnetic sensors encompass many aspects of physics and electronics. Thetechnologies used for magnetic field sensing include search coil,fluxgate, optically pumped, nuclear precession, SQUID, Hall-Effect,anisotropic magnetoresistance, giant magnetoresistance, magnetic tunneljunctions, giant magnetoimpedance, magnetostrictive/piezoelectriccomposites, magnetodiode, magnetotransistor, fiber optic, magnetooptic,and microelectromechanical systems-based magnetic sensors, among others.

In various instances, one or more of the position sensors of thetracking system 1860 comprise a magnetic rotary absolute positioningsystem. Such position sensors may be implemented as an AS5055EQFTsingle-chip magnetic rotary position sensor available from AustriaMicrosystems, AG and can be interfaced with the controller 1840 toprovide an absolute positioning system. In certain instances, a positionsensor comprises a low-voltage and low-power component and includes fourHall-Effect elements in an area of the position sensor that is locatedadjacent a magnet. A high resolution ADC and a smart power managementcontroller are also provided on the chip. A CORDIC processor (forCoordinate Rotation Digital Computer), also known as the digit-by-digitmethod and Volder's algorithm, is provided to implement a simple andefficient algorithm to calculate hyperbolic and trigonometric functionsthat require only addition, subtraction, bitshift, and table lookupoperations. The angle position, alarm bits, and magnetic fieldinformation are transmitted over a standard serial communicationinterface such as an SPI interface to the controller 1840. The positionsensors can provide 12 or 14 bits of resolution, for example. Theposition sensors can be an AS5055 chip provided in a small QFN 16-pin4×4×0.85 mm package, for example.

The tracking system 1860 may comprise and/or be programmed to implementa feedback controller, such as a PID, state feedback, and adaptivecontroller. A power source converts the signal from the feedbackcontroller into a physical input to the system, in this case voltage.Other examples include pulse width modulation (PWM) and/or frequencymodulation (FM) of the voltage, current, and force. Other sensor(s) maybe provided to measure physical parameters of the physical system inaddition to position. In various instances, the other sensor(s) caninclude sensor arrangements such as those described in U.S. Pat. No.9,345,481, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM,which is hereby incorporated herein by reference in its entirety; U.S.Patent Application Publication No. 2014/0263552, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which is hereby incorporatedherein by reference in its entirety; and U.S. patent application Ser.No. 15/628,175, entitled TECHNIQUES FOR ADAPTIVE CONTROL OF MOTORVELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENT, which is herebyincorporated herein by reference in its entirety. In a digital signalprocessing system, absolute positioning system is coupled to a digitaldata acquisition system where the output of the absolute positioningsystem will have finite resolution and sampling frequency. The absolutepositioning system may comprise a compare and combine circuit to combinea computed response with a measured response using algorithms such asweighted average and theoretical control loop that drives the computedresponse towards the measured response. The computed response of thephysical system takes into account properties like mass, inertial,viscous friction, inductance resistance, etc., to predict what thestates and outputs of the physical system will be by knowing the input.

The absolute positioning system provides an absolute position of thedisplacement member upon power up of the instrument without retractingor advancing the displacement member to a reset (zero or home) positionas may be required with conventional rotary encoders that merely countthe number of steps forwards or backwards that the motor 1610 has takento infer the position of a device actuator, drive bar, knife, and thelike.

A sensor 1880 comprising a strain gage or a micro-strain gage, forexample, is configured to measure one or more parameters of the endeffector, such as, for example, the strain experienced by the jaws 7110and 7120 during a clamping operation. The measured strain is convertedto a digital signal and provided to the processor 1820. In addition toor in lieu of the sensor 1880, a sensor 1890 comprising a load sensor,for example, can measure the closure force applied by the closure drivesystem to the jaws 7110 and 7120. In various instances, a current sensor1870 can be employed to measure the current drawn by the motor 1610. Theforce required to clamp the jaw assembly 7100 can correspond to thecurrent drawn by the motor 1610, for example. The measured force isconverted to a digital signal and provided to the processor 1820. Amagnetic field sensor can be employed to measure the thickness of thecaptured tissue. The measurement of the magnetic field sensor can alsobe converted to a digital signal and provided to the processor 1820.

The measurements of the tissue compression, the tissue thickness, and/orthe force required to close the end effector on the tissue as measuredby the sensors can be used by the controller 1840 to characterize theposition and/or speed of the movable member being tracked. In at leastone instance, a memory 1830 may store a technique, an equation, and/or alook-up table which can be employed by the controller 1840 in theassessment. In various instances, the controller 1840 can provide theuser of the surgical instrument with a choice as to the manner in whichthe surgical instrument should be operated. To this end, the display1440 can display a variety of operating conditions of the instrument andcan include touch screen functionality for data input. Moreover,information displayed on the display 1440 may be overlaid with imagesacquired via the imaging modules of one or more endoscopes and/or one ormore additional surgical instruments used during the surgical procedure.

As discussed above, the drive module 1100 of the handle 1000 and/or theshaft assemblies 2000, 3000, 4000, and/or 5000, for example, attachablethereto comprise control systems. Each of the control systems cancomprise a circuit board having one or more processors and/or memorydevices. Among other things, the control systems are configured to storesensor data, for example. They are also configured to store data whichidentifies the shaft assembly to the handle 1000. Moreover, they arealso configured to store data including whether or not the shaftassembly has been previously used and/or how many times the shaftassembly has been used. This information can be obtained by the handle1000 to assess whether or not the shaft assembly is suitable for useand/or has been used less than a predetermined number of times, forexample.

Further to the above, the first module connector 1120 of the drivemodule 1100 comprises a side battery port defined in the side of thedrive module 1100. Similarly, the second module connector 1120′comprises a proximal battery port defined in the proximal end of thedrive module 1100. That said, a drive module can comprise a battery portat any suitable location. In any event, the power module 1200 isoperably attachable to the drive module 1100 at the side battery port1120, as illustrated in FIGS. 54-58, or the proximal battery port 1120′,as illustrated in FIGS. 67 and 68. This is possible because theconnector 1220 of the power module 1200 is compatible with the sidebattery port 1120 and the proximal battery port 1120′. Among otherthings, the connector 1220 comprises a substantially circular, orsubstantially cylindrical, configuration that matches, or at leastsubstantially matches, the substantially circular, or substantiallycylindrical, configurations of the battery ports 1120 and 1120′. Invarious instances, the connector 1220 comprises a frustoconical, or anat least substantially frustoconical, shape having a bottom portionwhich is larger than the top portion and an angled, or tapered, sideextending therebetween. The above being said, the connector 1220 of thepower module 1200 does not comprise keys, or projections, extendingtherefrom which interfere with the assembly of the power module 1200 tothe battery ports 1120 and 1120′.

Referring primarily to FIGS. 55 and 56, the connector 1220 comprises twolatches 1240 extending therefrom. The latches 1240 are positioned onopposite sides of the connector 1220 such that they comprise opposinglatch shoulders which releasably hold the power module 1200 to thehandle module 1100. The side battery port 1120 comprises latch openings1125 defined in the housing 1100 which are configured to receive thelatches 1240 of the power module 1200 and, similarly, the proximalbattery port 1120′ comprises latch openings 1125′ defined in the housing1100 which are also configured to receive the latches 1240 of the powermodule 1200. While the latch openings 1125 in the side battery port 1120and the latch openings 1125′ in the proximal battery port 1120′ limitthe orientations in which the power module 1200 can be assembled to eachbattery port 1120 and 1120′, i.e., two orientations for each batteryport, the power module 1200 is nonetheless operably attachable to bothbattery ports 1120 and 1120′.

Further to the above, the latches 1240 of the power module 1200 areconfigured to engage the drive module 1100 in a snap-fit manner. Invarious instances, the latches 1240 resiliently flex radially outwardlywhen the power module 1200 is assembled to the drive module 1100 andthen resiliently move, or snap, radially inwardly once the power module1200 is fully seated within one of the ports 1120 and 1120′ to lock thepower module 1200 to the drive module 1100. In various instances, thelatches 1240 comprise flexible arms which deflect radially inwardly andoutwardly as described above while, in some instances, the latches 1240comprise one or more biasing members, such as springs, for example,configured to resiliently push the latches 1240 into their inward, orlocked, positions. In various embodiments, the power module 1200 cancomprise members which are press-fit into apertures defined in the ports1120 and 1120′ to retain the power module 1200 to the drive module 1100.

Further to the above, the electrical contacts of the power module 1200are defined on the top portion, or face, of the connector 1220. Asdiscussed above, the electrical contacts of the power module 1200 engagecorresponding electrical contacts defined in the ports 1120 and 1120′when the power module 1200 is attached to the drive module 1100 to placethe power module 1200 in electrical communication with the drive module1100. In various instances, the electrical contacts of the power module1200 are compressed against the electrical contacts of the drive module1100 when the power module 1200 is attached to the drive module 1100. Inat least one such instance, the power module contacts and/or the drivemodule contacts comprise resilient members which are configured toelastically deflect when the power module 1200 is attached to the drivemodule 1100. Such resilient members, along with the latches 1240, canassure that there is an adequate electrical interface between the powermodule 1200 and the drive module 1100. In alternative embodiments, thepower module 1200 can comprise annular electrical contacts extendingaround the perimeter thereof which engage electrical contacts on thesides of the ports 1120 and 1120′. Such an arrangement could permitrelative rotation between the power module 1200 and the drive module1100.

Further to the above, the power module 1300 is operably attachable tothe drive module 1100 at the proximal battery port 1120′, as illustratedin FIGS. 59-66, but not the side battery port 1120, as illustrated inFIGS. 69 and 70. This is the case because the connector 1320 of thepower module 1300 is compatible with the proximal battery port 1120′,but not the side battery port 1120. Although the connector 1320comprises a substantially circular, or substantially cylindrical,configuration that matches, or at least substantially matches, thesubstantially circular, or substantially cylindrical, configurations ofthe battery ports 1120 and 1120′, the connector 1320 of the power module1300 comprises keys, or projections, 1315 extending therefrom whichinterfere with the assembly of the power module 1300 to the side batteryport 1120, but not the proximal battery port 1120′. When a clinicianattempts to assembly the power module 1300 to the side battery port1120′, the projections 1315 contact the housing 1110 and prevent thelatches 1340 of the power module 1300 from locking the power module 1300to the drive module 1100 and prevent the power module 1300 from beingelectrically coupled to the drive module 1100. That being said,referring primarily to FIGS. 63 and 64, the proximal battery port 1120′comprises clearance apertures 1115′ defined therein configured toreceive the projections 1315 of the power module 1300 and permit thepower module 1300 to be assembled to the proximal battery port 1120′.Similar to the above, the latch openings 1125′ and the clearanceapertures 1115′ in the proximal battery port 1120′ limit theorientations in which the power module 1300 can be assembled to theproximal battery port 1120′ to two orientations.

Further to the above, other circumstances can prevent the attachment ofa power module to one of the battery ports 1120 and 1120′. For instance,one of the battery ports can have an asymmetrical geometry which isconfigured to receive a complementary geometry of only one of the powermodules. In at least one such instance, the side battery port 1120 cancomprise a semicircular cavity and the proximal battery port 1120′ cancomprise a circular cavity, wherein the connector 1220 of the powermodule 1200 comprises a semicircular geometry which can be received inboth of the battery ports 1120 and 1120′ while the connector 1320 of thepower module 1300 comprises a circular geometry which can be received inthe proximal battery port 1120′, but not the side battery port 1120. Insome instances, the configuration of the shaft assembly attached to thedrive module 1100 can prevent the assembly of one of the power modulesto the drive module 1100. For instance, referring to FIG. 59, the shaftassembly 4000, for example, can prevent the assembly of the power module1300 to the side battery port 1120 as the actuation trigger 4610interferes with its assembly thereto. Notably, such an arrangement wouldalso prevent the power module 1200 from being assembled to the sidebattery port 1120. As a result, the clinician would be required to usethe proximal battery port 1120′ to couple a power module to the drivemodule 1100 when using the shaft assembly 4000. The configuration ofcertain shaft assemblies, referring to FIGS. 71 and 72, would permitboth of the power modules 1200 and 1300 to be assembled to the drivemodule 1100 at the same time. For instance, referring to FIG. 51, theshaft assembly 3000 of FIG. 1 would permit both of the power modules1200 and 1300 to be used to supply power to the drive module 1100simultaneously.

The power modules 1200 and 1300 are configured to supply power to thedrive module 1100 at the same, or at least substantially the same,voltage. For instance, each power module 1200 and 1300 is configured tosupply power to the drive module 1100 at 3 VDC, for example. The controlsystem 1800 of the drive module 1100 comprises one or more powerinverters, for example, configured to convert the DC current to ACcurrent to the extent that AC current is needed. That said, the powermodules 1200 and 1300 can be configured to deliver power to the drivemodule 1100 at any suitable voltage. In at least one instance, the powermodules 1200 and/or 1300 are configured to deliver AC power to the drivemodule. In at least one such instance, the power modules 1200 and/or1300 each comprise one or more power inverters. In alternativeembodiments, the power modules 1200 and 1300 are configured to supplypower to the drive module 1100 at different voltages. In suchembodiments, the configurations of the ports 1120 and 1120′, discussedabove, can prevent a power module having a higher voltage from beingattached to a lower voltage port. Likewise, the configurations of theports 1120 and 1120′ can prevent a power module having a lower voltagefrom being attached to a higher voltage port, if desired.

In various instances, the power modules 1200 and 1300 are configured toprovide the same, or at least substantially the same, current to thedrive module. In at least one instance, the power modules 1200 and 1300supply the same, or at least substantially the same, magnitude ofcurrent to the drive module 1100. In alternative embodiments, the powermodules 1200 and 1300 are configured to provide different currents tothe drive module 1100. In at least one instance, the power module 1200provides a current to the drive module 1100 having a magnitude which istwice that of the current provided by the power module 1300, forexample. In at least one such instance, the battery cells of the powermodule 1200 are arranged in parallel to provide the same voltage as thepower module 1300 but at twice the current. Similar to the above, theconfigurations of the ports 1120 and 1120′, discussed above, can preventa power module having a higher current from being attached to a lowercurrent port. Likewise, the configurations of the ports 1120 and 1120′can prevent a power module having a lower current from being attached toa higher current port, if desired.

Further to the above, the control system 1800 is configured toadaptively manage the power provided by the power modules 1200 and 1300.In various instances, the control system 1800 comprises one or moretransformer circuits configured to step up and/or step down the voltageprovided to it by a power module. For instance, if a higher voltagepower module is attached to a lower voltage port, the control system1800 can activate, or switch on, a transformer circuit to step down thevoltage from the higher voltage power module. Similarly, if a lowervoltage power module is attached to a higher voltage port, the controlsystem 1800 can activate, or switch on, a transformer circuit to step upthe voltage from the lower voltage power module. In various embodiments,the control system 1800 is configured to switch a power module off if apower module having an inappropriate voltage is attached to a port inthe drive module 1100. In at least one instance, the control system 1800comprises one or more voltmeter circuits configured to evaluate thevoltage of a power module attached to the drive module and, if thevoltage of the power module is incorrect or outside of an appropriatevoltage range, the control system 1800 can switch off the power modulesuch that the power module does not supply power to the drive module1100. In at least one such instance, the drive module 1100 has avoltmeter circuit for each port 1120 and 1120′. In at least oneinstance, the control system 1800 comprises one or more ammeter circuitsconfigured to evaluate the current of a power module attached to thedrive module and, if the current of the power module is incorrect oroutside of an appropriate current range, the control system 1800 canswitch off the power module such that the power module does not supplypower to the drive module 1100. In at least one such instance, the drivemodule 1100 has an ammeter circuit for each port 1120 and 1120′. In atleast one instance, each power module 1200 and 1300 comprises a switchcircuit which, when opened by the control system 1800, prevents powerfrom being supplied to the drive module 1100. If a power modulecomprises the correct voltage or a voltage within an appropriate voltagerange for the port in which the power module is attached, the switchcircuit remains closed and/or is closed by the control system 1800. Inat least one such instance, the drive module 1100 has a switch circuitfor each port 1120 and 1120′.

In various instances, a power module can comprise a switch which isselectively actuatable by the clinician to prevent the power module fromsupplying power to the drive module 1100. In at least one instance, theswitch comprises a mechanical switch, for example, in the power supplycircuit of the power module. A power module that has been switched off,however, can still provide other benefits. For instance, a switched-offpower module 1200 can still provide a pistol grip and a switched-offpower module 1300 can still provide a wand grip. Moreover, in someinstances, a switched-off power module can provide a power reserve thatcan be selectively actuated by the clinician.

In addition to or in lieu of the above, each of the power modules 1200and 1300 comprises an identification memory device. The identificationmemory devices can comprise a solid state chip, for example, having datastored thereon which can be accessed by and/or transmitted to thecontrol system 1800 when a power module is assembled to the drive module1100. In at least one instance, the data stored on the identificationmemory device can comprise data regarding the voltage that the powermodule is configured to supply to the drive module 1100, for example.

Further to the above, each of the shaft assemblies 2000, 3000, 4000,and/or 5000 comprise an identification memory device, such as memorydevice 2830, for example. The identification memory device of a shaftassembly can comprise a solid state chip, for example, having datastored thereon which can be accessed by and/or transmitted to thecontrol system 1800 when the shaft assembly is assembled to the drivemodule 1100. In at least one instance, the data stored on theidentification memory device can comprise data regarding the powerrequired to operate the drive systems of the shaft assembly. The shaftassembly 2000 comprises three systems driven by the drive module1100—the end effector articulation drive system, the end effectorrotation drive system, and the jaw drive system—each of which havingtheir own power requirement. The jaw drive system, for instance, mayrequire more power than the end effector articulation and rotation drivesystems. To this end, the control system 1800 is configured to verifythat the power provided by the power module, or power modules, attachedto the drive module 1100 is sufficient to power all of the drivesystems—including the jaw drive system—of the shaft assembly 2000assembled to the drive module 1100. As such, the control system 1800 isconfigured to assure that the power module arrangement attached to thedrive module 1100 is properly paired with the shaft assembly attached tothe drive module 1100. If the power provided by the power modulearrangement is insufficient, or below a required power threshold, thecontrol system 1800 can inform the clinician that a different and/or anadditional power module is required. In at least one instance, the drivemodule 1100 comprises a low-power indicator on the housing 1110 and/oron the display screen 1440, for example. Notably, the jaw drive systemof the shaft assembly 4000 is not driven by the drive module 1100;rather, it is manually powered by the clinician. As such, the powerrequired to operate the shaft assembly 4000 can be less than the powerrequired to operate the shaft assembly 2000, for example, and thecontrol system 1800 can lower the required power threshold for the shaftassembly 4000 when evaluating the power module arrangement.

Further to the above, an end effector configured to grasp and/or dissecttissue may require less power than an end effector configured to clipthe tissue of a patient. As a result, an end effector and/or shaftassembly comprising a clip applier may have a larger power requirementthan an end effector and/or shaft assembly comprising grasping and/ordissecting jaws. In such instances, the control system 1800 of the drivemodule 1100 is configured to verify that the power module, or modules,attached to the drive module 1100 can provide sufficient power to thedrive module 1100. The control system 1800 can be configured tointerrogate the identification chips on the power modules attached tothe drive module 1100 and/or evaluate the power sources within the powermodules to assess whether the power modules comprisesufficiently-available voltage and/or current to properly power thedrive module 1100 to operate the clip applier.

Further to the above, an end effector configured to grasp and/or dissecttissue may require less power than an end effector configured to suturethe tissue of a patient, for example. As a result, an end effectorand/or shaft assembly comprising a suturing device may have a largerpower requirement than an end effector and/or shaft assembly comprisinggrasping and/or dissecting jaws. In such instances, the control system1800 of the drive module 1100 is configured to verify that the powermodule, or modules, attached to the drive module 1100 can providesufficient power to the drive module 1100 based on the shaft assemblyattached to the drive module 1100. The control system 1800 can beconfigured to interrogate the identification chips on the power modulesattached to the drive module 1100 and/or evaluate the power sourceswithin the power modules to assess whether the power modules comprisesufficiently-available voltage and/or current to properly power thedrive module 1100 to operate the suturing device.

In addition to or in lieu of the above, an end effector, such as endeffector 7000, for example, comprises an identification memory device.The identification memory device of an end effector can comprise a solidstate chip, for example, having data stored thereon which can beaccessed by and/or transmitted to the control system 1800 when the endeffector is assembled to the drive module 1100 by way of a shaftassembly. In at least one instance, the data stored on theidentification memory device can comprise data regarding the powerrequired to operate the drive systems of the end effector. The endeffector can be in communication with the drive module 1100 throughelectrical pathways, or circuits, extending through the shaft assembly.Similar to the above, the end effector can identify itself to the drivemodule 1100 and, with this information, the drive module 1100 can adaptits operation to properly operate the end effector.

As described above, the power modules 1200 and 1300 each comprise one ormore battery cells. That said, the power modules 1200 and 1300 cancomprise any suitable means for storing and delivering power. In atleast one instance, the power modules 1200 and 1300 comprise capacitorsand/or supercapacitors configured to store energy and deliver energy tothe drive module 1100. The capacitors and/or supercapacitors can be partof the same electrical circuit as the battery cells or a differentelectrical circuit. A supercapacitor can comprise electrostaticdouble-layer capacitance and/or electrochemical pseudocapacitance, bothof which can contribute to the total capacitance of the supercapacitor.In various instances, electrostatic double-layer capacitors use carbonelectrodes or derivatives with much higher electrostatic double-layercapacitance than electrochemical pseudocapacitance, achieving separationof charge in a Helmholtz double layer at the interface between thesurface of a conductive electrode and an electrolyte. The separation ofcharge is often of the order of a few angstroms (0.3-0.8 nm), muchsmaller than in a conventional capacitor. Electrochemicalpseudocapacitors use metal oxide or conducting polymer electrodes with ahigh amount of electrochemical pseudocapacitance additional to thedouble-layer capacitance. Pseudocapacitance is achieved by Faradaicelectron charge-transfer with redox reactions, intercalation, and/orelectrosorption. Hybrid capacitors, such as a lithium-ion capacitor, forexample, could also be used which comprise electrodes with differingcharacteristics—one exhibiting mostly electrostatic capacitance and theother mostly electrochemical capacitance.

The power modules 1200 and 1300 can be rechargeable or non-rechargeable.When the power modules 1200 and 1300 are not rechargeable, they aredisposed of after a single use. In such instances, it is desirable forthe power modules 1200 and 1300 to be completely drained, or at leastsubstantially drained, of power when they are disposed of. To this end,each power module comprises a drain which is engaged, or actuated, whenthe power module is assembled to the drive module 1100. In variousinstances, the drain comprises a resistance circuit inside the powermodule that includes the battery cells. Once actuated, the drain slowlydischarges the battery cells of the power module, but at a rate whichstill permits the power module to provide sufficient power to the drivemodule 1100 during the surgical procedure. After the surgical procedureis completed, however, the drain continues to discharge the batterycells even though the power module may no longer be assembled to thedrive module 1100. As such, the drain discharges the battery cellswhether or not the power module is supplying power to, or attached to,the drive module 1100. The entire disclosures of U.S. Pat. No.8,632,525, entitled POWER CONTROL ARRANGEMENTS FOR SURGICAL INSTRUMENTSAND BATTERIES, which issued on Jan. 21, 2014, and U.S. Pat. No.9,289,212, entitled SURGICAL INSTRUMENTS AND BATTERIES FOR SURGICALINSTRUMENTS, which issued on Mar. 22, 2016, are incorporated byreference herein.

Multiple surgical instruments, including various handheld instruments,are used by a clinician during a particular surgical procedure toperform different functions. Each surgical instrument may comprisedifferent handle and/or grip configurations in addition to differentuser control mechanisms. Switching between various handheld instrumentsmay cause delay and/or discomfort, as the clinician regains control overthe surgical instrument and actuates the user control mechanism(s). Theuse of numerous powered surgical instruments may require a user toensure that, prior to the start of every surgical procedure, numerouspower sources are charged and/or functional, as power sources may varyand/or may not compatible with all powered surgical instruments.

A modular surgical instrument comprising a universal handle and powersource may provide a clinician with a sense of familiarity in using auniversal handle configuration. The modular surgical instrument isconfigured for use with numerous surgical tool attachments. Instead ofhaving to charge a plurality of different power sources, the modularsurgical instrument is configured for use with a replaceable powersource that can be discarded after each surgical procedure. Furthermore,the use of one universal handle with a plurality of surgical toolattachments may reduce the clutter and/or volume of surgical instrumentswithin the surgical arena.

FIG. 73 illustrates a portion of a modular surgical instrument 80000 andFIG. 74 illustrates an electrical architecture of the modular surgicalinstrument 80000. The configuration of the modular surgical instrument80000 is similar in many respects to the surgical instrument 1000 inFIG. 1 discussed above. The modular surgical instrument 80000 comprisesa plurality of modular components, including, for example: a drivemodule 80010, a shaft 80020, an end effector 80030, and a power source80040. In various instances, the drive module 80010 comprises a handle.The drive module 80010 comprises one or more control switches 80012 anda motor 80015.

The shaft 80020 comprises a control circuit 80022 configured tofacilitate communication between the modular components 80010, 80020,80030, 80040 of the surgical instrument 80000. The operation andfunctionality of the modular components 80010, 80020, 80030, 80040 ofthe surgical instrument 80000 are described in greater detail above inconnection with other surgical instruments.

In various instances, the one or more control switches 80012 correspondto the rotation actuator 1420 and the articulation actuator 1430 of theinput system 1400 as described in greater detail with respect to FIGS. 7and 8 above. As shown in FIGS. 7 and 8, the articulation actuator 1430comprises a first push button 1432 and a second push button 1434. Thefirst push button 1432 comprises a first switch that is closed when thefirst push button 1434 is depressed. Similar in many aspects to thearticulation actuator 1430 and the rotation actuator 1420 shown in FIGS.7 and 8, the one or more control switches 80012 may comprise pushbuttons. When a user input depresses the push button, a switch is closedthat sends a signal to the control circuit 80022 indicative of a usercommand. In various instances, a first push button can initiatearticulation or rotation in a first direction while a second push buttoncan initiate articulation or rotation in a second direction. Theoperation and functionality of these control switches 80012 aredescribed in greater detail above.

In various instances, the shaft 80020 is configured to be disposableafter being used to treat a patient. In such instances, the shaft 80020is usable more than once on the same patient. As discussed in moredetail below, the shaft 80020 comprises a processor 80024 and a memorystoring instructions for one or more control programs. The disposableshaft 80020 comprises any signal processing circuits required tointerface with the end effector 80030, the power source 80040, and/orthe drive module 80010 when the modular surgical instrument 80000 isfully configured, or assembled. The end effector 80030 comprises asensor array 80035 configured to monitor a parameter of the end effector80030. Such a sensor array 80035 can detect, for example, informationpertaining to the identity of the end effector 80030, an operatingstatus of the end effector 80030, and/or information regarding theenvironment of the surgical site, such as tissue properties, forexample. In various instances, the power source 80040 comprises areplaceable battery pack configured to be attached directly to the drivemodule 80010 to supply power to the surgical instrument 80000. The powersource 80040 comprises a battery 80042 and a display 80044. In variousinstances the display 80044 comprises a touch-sensitive display, forexample, wherein a user input is sent to the processor 80024.

In various instances, the drive module 80010 comprises a power sourceinterface for attaching the modular power source 80040 thereto. Thereplaceable connection between the power source 80040 and the drivemodule 80010 allows for a user to readily change out the power source80040 without having to disassemble a housing of the drive module 80010.The battery 80042 within the modular power source 80040 comprises aprimary cell, but can also include secondary cells. The primary cellbattery 80042 is configured to be fully charged once. In other words,the primary cell battery 80042 is configured to be discarded after eachsurgical procedure. Use of a disposable power supply may, among otherthings, provide assurance to the clinician that the battery 80042 isfully charged at the beginning of each surgical procedure.

The power source interface supplies the interconnection between thebattery 80042 and the connection of the display 80044 upon theattachment of the power source 80040 to the drive module 80010. In otherwords, no continuous circuits are present within the power source 80040until the power source 80040 is replaceably attached to the power sourceinterface on the drive module 80010. As such, the power source 80040 canbe distributed and sterilized in an uncoupled state. The ability to bein an uncoupled state permits each power source 80040 to be easilysterilized. For example, the modular power source 80040 is compatiblewith both ethylene oxide and gamma sterilization as no continuouscircuits are present in the unattached power source 80040.

Similar to the power source 80040, the drive module 80010 does not haveany continuous circuits while unattached to the shaft 80020 and thepower source 80040. For at least this reason, the drive module 80010 isable to be sterilized using any desired sterilization protocol followingeach use. In its unattached configuration, the drive module 80010 isconfigured to be tolerant of full immersion during the cleaning process.

Further to the above, the control circuit 80022 of the shaft 80020comprises a processor 80024 configured to receive a user input from theone or more control switches 80012 on the drive module 80010. The shaft80020 further comprises a motor controller 80028 configured to controlthe motor 80015 within the drive module 80010 when the shaft 80020 isassembled to the drive module 80010. In various instances, the controlcircuit 80022 further comprises a safety processor 80024 comprising twocontroller-based families such as, for example, TMS570 and RM4x knownunder the trade name Hercules ARM Cortex R4, by Texas Instruments. Thesafety processor 80026 may be configured specifically for IEC 61508 andISO 26262 safety critical applications, among others, to provideadvanced integrated safety features while delivering scalableperformance, connectivity, and memory options. The safety processor80026 is configured to be in signal communication with the processor80024 and the motor controller 80028. The motor controller 80028 isconfigured to be in signal communication with the sensor array 80035 ofthe end effector 80030 and the motor 80015 within the handle 80010. Themotor controller 80028 is configured to send an electrical signal, suchas, for example, a voltage signal, indicative of the voltage (or power)to be supplied to the motor 80015. The electrical signal may bedetermined based off of, for example, user input from the one or morecontrol switches 80012, input received from the sensor array 80035, userinput from the display 80044, and/or feedback from the motor 80015. Invarious instances, the motor controller 80028 may output a PWM controlsignal to the motor 80015 in order to control the motor 80015.

The shaft 80020 further comprises a memory configured to store controlprograms which, when executed, prompt the processor to, among otherthings, command the motor controller 80028 to activate the motor 80015at a pre-determined level. The memory within the control circuit 80022of each shaft 80020 is configured to store one or more control programsto permit the modular surgical instrument 80000, when fully configured,to perform a desired function. In various instances, the shaft 80020 maycomprise a default control program for when the attached shaft 80020does not comprise a control program and/or a stored control programcannot be read or detected. Such a default control program permits themotor 80015 to be run at a minimum level to allow a clinician to performbasic functions of the modular surgical instrument 80000. In variousinstances, only basic functions of the modular surgical instrument 80000are available in the default control program and are performed in amanner that minimizes harm to the tissue in and/or surrounding thesurgical site. Storing control program(s) specific to an intendedfunction in each replaceable shaft 80020 minimizes the amount ofinformation that needs to be stored and, thus, relieves the drive module80010 of the burden of storing all possible control programs, many ofwhich go unused. In various instances, the modular components 80010,80020, 80030, 80040 of the surgical instrument 80000 can be designed,manufactured, programmed, and/or updated at different times and/or inaccordance with different software and/or firmware revisions andupdates. Furthermore, individual control programs can be updated morequickly than a collection of numerous control programs. The fasterupdate time makes it more likely that clinicians and/or assistants willupdate the control program(s) to utilize the most up-to-date program ineach surgical procedure. In various instances, the drive module 80010may not comprise any control programs. In other instances, the drivemodule 80010 may comprise a default control program as discussed above.In other words, if a clinician intends to perform a first function, theclinician may attach a first shaft comprising a stored first controlprogram to the modular surgical instrument. If the clinician intends toperform a second function that is different from the first function, theclinician may remove the first shaft from the universal drive module andattach a second shaft comprising a stored second control program to themodular surgical instrument. In various instances, if the clinicianattaches a shaft without a detectable and/or functional stored controlprogram, the drive module 80010 may comprise a memory storing a defaultcontrol program to operate the modular surgical instrument 80000 atminimum levels and/or at any suitable level of functionality. Theoperation and functionality of the stored control programs are describedin greater detail in U.S. patent application Ser. No. 14/226,133, nowU.S. Patent Application Publication No. 2015/0272557, entitled MODULARSURGICAL INSTRUMENT SYSTEM, which is incorporated by reference in itsentirety herein.

FIG. 75 depicts a drive module 80110 comprising a plurality of drivesconfigured to interact with corresponding drives in an attached shaft toproduce a desired function, such as, for example, rotation and/orarticulation of an end effector. For example, the drive module 80110comprises a rotation drive 80120 configured to rotate an end effectorupon actuation. The drive module 80110 of FIG. 75 is configured tooperate based on the type of handle attached to the modular shaft. Oneor more of the plurality of drives is decoupled when a low-functionalityhandle, such as, for example, a scissor grip handle, is attached to themodular shaft. For example, during the attachment of a low-functionalityhandle to the modular shaft, an extending lug on the low-functionalityhandle may cause the rotation drive 80120 to advance distally out ofengagement with the low-functionality handle. Such distal advancementresults in a decoupling of the rotation drive 80120 from the handle,effectively locking out the functionality of the rotation drive 80120.Upon detachment of the scissor grip handle from the modular shaft, aresilient member 80125, such as, for example, a spring, biases therotation drive 80120 proximally into its original position. In variousinstances, all of the drives are decoupled upon the attachment of thelow-functionality handle to the modular shaft. In other instances, afirst drive, such as, for example, the rotation drive 80120, may bedecoupled upon the attachment of the low-functionality handle to themodular shaft, while a second drive 80130 remains in engagement for usewith the low-functionality handle.

In various instances, the rotation drive 80120 is in communication witha manual rotation actuator, such as the rotation actuator 1420 describedin more detail above with respect to FIGS. 8, 10, and 11. As a clinicianrotates the rotation actuator, the position of the rotation actuator canbe monitored. For instance, the surgical instrument can comprise anencoder system configured to monitor the position of the rotationactuator. In addition to or in lieu of the encoder system, the drivemodule 80110 can comprise a sensor system configured to detect a degreeof rotation of the rotation actuator. In any event, the detectedposition of the rotation actuator is communicated to a processor and amotor controller, such as processor 80024 and motor controller 80028within the shaft 80020. In various instances, the drive module 80110comprises a handle.

The processor 80024 and the motor controller 80028 are configured todrive a system of the shaft 80020 other than the system being manuallydriven by the rotation drive 80120 in response to the movement of therotation drive 80120. In at least one instance, a surgical instrumenthas a first rotation joint and a second rotation joint where therotation of the surgical instrument about the first rotation joint ismanually driven and the rotation of the surgical instrument about thesecond rotation joint is driven by an electric motor. In such aninstance, the processor 80024 can monitor the rotation of the surgicalinstrument about the first rotation joint using the encoder and rotatethe surgical instrument about the second rotation joint using the motorcontroller 80028 in order to keep the rotatable components of thesurgical instrument aligned, for example.

FIG. 76 depicts a handle 80210 prior to engagement with aninterchangeable shaft 80220. The handle 80210 is usable with severalinterchangeable shafts and can be referred to as a universal handle. Theshaft 80220 comprises a drive rod 80250 configured to mechanicallyengage a distal nut 80255 of the handle 80210. A proximal end 80251 ofthe drive rod 80250 comprises a specific geometry configured to fitwithin a recess 80256 defined in the distal end of the distal nut 80255.The recess 80256 within the distal nut 80255 comprises a geometry thatis complementary of the geometry of the proximal end 80251 of the driverod 80250. In other words, once the clinician and/or the assistant hasoriented the shaft 80220 in a manner that allows for the drive rod 80250to fit within the recess on the distal nut 80255 of the handle 80210,the interchangeable shaft 80220 is successfully aligned with theuniversal handle 80210 such that there is little, if any, relativelateral movement between the distal nut 80255 and the drive rod 80250.

In various instances, the distal end 80211 of the drive nut 80255 andthe proximal end 80223 of the drive rod 80250 comprise a plurality ofmagnetic elements 80260, 80265, 80270 configured to facilitate alignmentof the shaft 80220 with the handle 80210 in addition to or in lieu ofthe mechanical alignment system described above. The system of magneticelements 80260, 80265, 80270 allows for self-alignment of the shaft80220 with the handle 80210. In various instances, the plurality ofmagnetic elements 80260, 80265, 80270 are permanent magnets. As seen inFIG. 75, the proximal end 80223 of the shaft 80220 comprises a pluralityof magnetic elements 80260, 80265 that are oriented asymmetrically,although the magnetic elements 80260, 80265 may be arranged in anysuitable manner. The magnetic elements 80260, 80265 are positioned withopposing poles facing outward from the proximal end 80223 of the shaft80220. More specifically, the magnetic elements 80260 positioned on afirst portion of the shaft 80220 are positioned with their positivepoles facing outward from the proximal end 80223, while the magneticelements 80265 positioned on a second, or opposite, portion of the shaft80220 are positioned with their negative poles facing outward from theproximal end 80223. The distal end 80211 of the drive nut 80255comprises a plurality of magnetic elements 80270 positioned with theirnegative poles facing outward from the distal end 80211 of the handle80210. Such an asymmetric pattern of magnetic elements 80260, 80265 onthe shaft 80220 can permit the shaft 80220 and the handle 80210 to bealigned at one or more predefined locations, as described in greaterdetail below. The use of magnetic elements 80260, 80265, 80270eliminates the need for a spring mechanism to shift the handle 80210 andthe shaft 80220 into predetermined positions.

Further to the above, if the clinician attempts to align the handle80210 with the shaft 80220 such that the magnetic elements 80270positioned on the handle 80210 are within the vicinity of the magneticelements 80260 positioned on a first portion of the shaft 80220, themagnetic elements 80260, 80270 produce an attractive magnetic force,thereby pulling the modular components 80210, 80220 into alignment.However, if the clinician attempts to align the handle 80210 with theshaft 80220 such that the magnetic elements 80270 positioned on thehandle 80210 are closer in vicinity to the magnetic elements 80265positioned on a second portion of the shaft 80220, a repulsive magneticforce will push the modular components 80210, 80220 apart, therebypreventing an improper connection between the handle 80210 and the shaft80220.

In certain instances, further to the above, only one stable positionwill exist between the modular components. In various instances, aplurality of magnetic elements are positioned so that their polesalternate in a repeating pattern along the outer circumferences of thedistal end of the handle 80210 and the proximal end of the shaft 80220.Such a pattern can be created in order to provide for a plurality ofstable alignment positions. The repeating pattern of magnetic elementsallows for a series of stable alignments between the shaft and thehandle, as an attractive magnetic force draws the modular components80210, 80220 together at numerous positions. In various instances, theplurality of magnetic elements are oriented in a way to create abi-stable magnetic network. Such a bi-stable network ensures that themodular components 80210, 80220 end in a stable alignment even when themodular components 80210, 80220 are initially misaligned. In otherwords, when the handle 80210 and the shaft 80220 are misaligned, themagnetic fields created by the plurality of magnetic elements interactwith one another to initiate rotation out of the misaligned position andinto the next closest stable alignment. Thus, the repulsive magneticforce experienced by misaligned modular components 80210, 80220 assistsin transitioning the modular components 80210, 80220 into alignment. Asthe modular components 80210, 80220 are pushed apart by the repulsivemagnetic force, they rotate into an attractive magnetic field therebyaligning the handle 80210 and the shaft 80220. In various instances, therepulsive magnetic force initiates rotation of the handle with respectto the shaft and vice versa. The pattern of the orientation of themagnetic elements can direct the modular components 80210, 80220 torotate in a particular direction with respect to one another while alsopreventing rotation in the opposite direction. For example, in variousinstances, the magnetic elements are oriented in a pattern that allowsfor the shaft 80220 and the handle 80210 to achieve alignment byrotating with respect to one another only in a clockwise direction whena repulsive magnetic force is experienced. In other instances, themagnetic elements are oriented in a pattern that allows for the shaft80220 and the handle 80210 to reach alignment by rotating with respectto one another only in a counterclockwise direction when a repulsivemagnetic force is experienced. In various instances, the magneticelements can impact the speed with which the modular components arebrought into alignment. For example, magnetic elements can be arrangedbased on the strength of their magnetic fields in order to causeacceleration or deceleration into or out of alignment. While theplurality of magnetic elements 80260, 80265, 80270 are described aboveas being permanent magnets, in certain instances, the plurality ofmagnetic elements 80260, 80265, 80270 are electromagnets. In suchinstances, magnetic repulsive and attractive forces can be created byselectively energizing the plurality of magnetic elements 80260, 80265,80270.

In various instances, the handle 80210 and the shaft 80220 comprise adominant magnetic element that provides an initial attractive magneticforce, wherein the dominant magnetic elements are configured to pull themodular components 80210, 80220 closer together. After the modularcomponents 80210, 80220 are drawn together by the dominant magneticelements, the plurality of magnetic elements 80260, 80265, 80270 areconfigured to finely adjust the orientations of the handle 80210 and theshaft 80220.

FIG. 77 depicts a universal handle 80310 prior to being aligned with andattached to a shaft 80320. The proximal end 80323 of the shaft 80320comprises a pin 80322 configured to engage an L-shaped, or bayonet, slot80312 cut into the distal end 80311 of the handle 80310. In variousinstances, a plurality of L-shaped slots 80312 may be cut around thecircumference of the distal end 80311 to provide additional attachmentsupport for additional pins 80322. The proximal end 80323 of the shaft80320 further comprises a frame and a shaft magnetic element 80324positioned in the frame with its positive pole facing outward. Thedistal end 80311 of the handle 80310 further comprises a first magneticelement 80314 and a second magnetic element 80316. The first magneticelement 80314 is oriented with its positive pole facing outwardly, andthe second magnetic element 80316 is oriented with its negative polefacing outwardly. As the clinician begins aligning the pin 80322 of theshaft 80320 with its corresponding L-shaped slot 80312 in the handle80310, the first magnetic element 80314 and the shaft magnetic element80324 interact to produce a repulsive magnetic force. The clinician mustovercome this force in order to engage the pin 80322 with the L-shapedslot 80312. Once the pin 80322 is within the L-shaped slot 80312 and/oronce the shaft magnetic element 80324 is moved past a threshold distancewith respect to the first magnetic element and the second magneticelement 80314 and 80324, the clinician can begin to manually rotate themodular components 80310, 80320 with respect to one another. Inaddition, as shown in FIG. 78, once the clinician has overcome therepulsive magnetic force to position the pin 80322 within the L-shapedslot 80312, the magnetic elements 80324, 80316 can react to create anattractive magnetic force once the shaft magnetic element 80324 is pastthe threshold. The attractive magnetic force results in rotation of theshaft 80320 with respect to the handle 80310 and full engagement of thepin 80322 into the L-shaped slot 80312. In such instances, theinteraction between the magnetic fields of the shaft magnetic element80324 and the second magnetic element 80316 on the handle 80310 isstrong enough to pull and/or hold the modular components 80310, 80320together. In various instances, such interaction results in anattractive magnetic force between the shaft magnetic element 80324 andthe second magnetic element 80316, resulting in alignment of the modularcomponents 80310, 80320 and full engagement of the pin 80322 within theL-shaped slot 80312. While the orientations of the magnetic elements arespecifically described, it is envisioned that the magnetic elements canbe oriented in any suitable manner. While the plurality of magneticelements 80314, 80316, 80324 are described above as being permanentmagnets, in certain instances, the plurality of magnetic elements 80314,80316, 80324 are electromagnets. In such instances, magnetic repulsiveand attractive forces can be created by selectively energizing theplurality of magnetic elements 80314, 80316, 80324.

The magnetic elements described above can comprise electromagnets,permanent magnets, or a combination thereof. In instances, such as thosedescribed above, a system of permanent magnetic elements may align theshaft and the handle in a plurality of positions. In such instances, anelectromagnet can be added to the system of permanent magnetic elements.When activated, the electromagnet is configured to exert a strongermagnetic field than the magnetic fields within the system of permanentmagnetic elements. In other words, an electromagnet may be incorporatedin order to interrupt, thwart, and/or change the cooperation between thesystem of permanent magnets. Such an interruption results in the abilityto exert selective control over the alignment of the modular componentsof the surgical instrument. For example, when a system of magneticelements, such as the magnetic elements 80260, 80265, 82070 in FIG. 76,have drawn the shaft 80220 and the handle 80210 together in a suitablyaligned position, a clinician may selectively activate an electromagnetto produce a magnetic field strong enough to overcome the attractivemagnetic forces of the permanent magnets and repel the shaft away fromthe handle. In various instances, activation of the electromagnet repelsthe handle away from the shaft to release or unlock the shaft from thehandle. In various instances, the activation of the electromagnet isconfigured to not only disrupt the attraction created by the permanentmagnets but also to decouple the modular components 80210, 80220.

A modular surgical instrument, such as the surgical instrument 80000shown in FIG. 73, for example, comprises a plurality of componentsconfigured to communicate with one another in order to perform anintended function of the surgical instrument. The communication pathwaysbetween the components of the modular surgical instrument are describedin detail above. While such communication pathways can be wireless innature, wired connections are also suitable. In various instances, theend effector and/or shaft of the surgical instrument are configured tobe inserted into a patient through a trocar, or cannula, and can haveany suitable diameter, such as approximately 5 mm, 8 mm, and/or 12 mm,for example. In addition to size constraints, various modular surgicalinstruments, such as, for example, a clip applier, comprise endeffectors and/or shafts that are configured to rotate and/or articulate,for example. Thus, any wired communication pathway must be compact andhave flexibility in order to maintain functionality as the end effectorand/or shaft is rotated and/or articulated. In an effort to reduce thesize of operational elements within a shaft and/or end effector of asurgical instrument, various micro electro-mechanical functionalelements may be utilized. Incorporating micro-electronics such as, forexample, a piezo inchworm actuator or a squiggle motor into a surgicalinstrument assists in reducing the space needed for operationalelements, as a squiggle motor, for example, is configured to deliverlinear movement without gears or cams.

In various instances, flexibility is built into the wired communicationpathway(s) by mounting various electrical traces on a flexiblesubstrate. In various instances, the electrical traces are supported onthe flexible substrate in any suitable manner. FIG. 79 depicts a flexcircuit 80400 for use in a modular surgical instrument, such as thesurgical instrument 1000, for example. The flex circuit 80400 isconfigured to extend within a housing of a shaft, such as the shaft80020 of FIG. 73. A distal end 80401 of the flex circuit 80400 isconfigured to be electrically coupled with conductive electrical traceswithin an end effector. In at least one instance, the electrical tracesare comprised of copper and/or silver, for example. The distal end 80401is wrapped into a first ring 80402, and the electrical traces 80405extend around the first ring 80402. A proximal end 80403 of the flexcircuit 80400 is configured to be electrically coupled with electricaltraces within a handle. The proximal end 80403 is wrapped into a secondring 80404, and the electrical traces 80405 extend around the secondring 80404.

While supporting various electrical traces on the flexible substrateprovides for flexibility, additional features may be added to, amongother things, increase the longevity of and/or protect the integrity ofthe flex circuit 80400. As depicted in FIGS. 79 and 79A, a primarystrain relief region 80410 is configured to be positioned proximally toan articulation joint. The primary strain relief region 80410 of theflex circuit 80400 experiences the most displacement and/or twisting inresponse to articulation of the surgical instrument. In an effort to,for example, relieve the strain on the flex circuit 80400 while thesurgical instrument is articulated and/or assist the portion of the flexcircuit 80400 within the primary strain relief region 80410 to return toits original orientation after the surgical instrument is unarticulated,one or more biasing and/or resilient members 80412 are present forresiliency and/or flexibility. The one or more biasing members 80412 areconfigured to transition between a flexed state and an un-flexed state,as the surgical instrument is articulated and/or rotated. In variousinstances, the biasing members 80412 comprise springs. The biasingmembers 80412 are incorporated into the substrate of the flex circuit80400 in an effort to, for example, accommodate for motions ofsurrounding parts. The portion of the flex circuit 80400 within theprimary strain relief region 80410 comprises a pattern comprising afirst leg 80414, a base 80416, and a second leg 80418. The base 80416extends between the first leg 80414 and the second leg 80418. Thebiasing member 80412 extends between and connects the first leg 80414and the second leg 80418. The biasing member 80412, among other things,permits the first leg 80414 to be deflected relative to the second leg80418 and then resiliently returns to its unflexed state. The biasingmember 80412 is configured to flex into the flexed state when an endeffector is articulated, and the biasing member 80412 is configured toresiliently return to the un-flexed state when the end effector is nolonger articulated.

As seen in FIGS. 79 and 79B, the flex circuit 80400 is manufactured witha secondary strain relief region 80420 whose conductive elements 80405are separate and not interconnected. Such orientation of the conductiveelements 80405 allows for the flex circuit 80400 to be folded. Thenon-fatiguing and flexible portions of the flex circuit 80400 arepositioned perpendicular to the flex circuit 80400 within the primarystrain relief region 80410. The secondary strain relief region 80420comprises one or more biasing members 80422, similar to the biasingmembers 80412 described in greater detail above. The presence of biasingmembers 80412 within the primary strain relief region 80410 and thebiasing members 80422 within the secondary strain relief portion 80320allows the flex circuit 80400 to have a stretchable portion in at leasttwo separate planes relative to a longitudinal axis of the shaft, suchas the shaft 80020 of FIG. 73, for example. The presence of the primarystrain relief portion 80410 in a first plane and a secondary strainrelief portion 80320 in a second plane allows for communication betweenan end effector, a shaft assembly, and a handle of a surgical instrumentconfigured to articulate the end effector, rotate the end effector, androtate the shaft assembly. In another instance, the flex circuit 80400can be manufactured flat and subsequently twisted in a portion, such asthe primary strain relief region 80410, which correlates to thearticulating or actuating portion of the surgical instrument. Such adesign may mitigate the need for stress relief of the flex circuit 80400in general.

FIG. 79C depicts a portion of the flex circuit 80400 of FIG. 79characterized by a printed circuit board (PCB) integrally formed withthe flexible substrate 80430 of the flex circuit 80400. As shown in FIG.79C, flexible plastic is over molded onto the conductive elements 80405and various control circuit components 80432, 80434, 80436 areintegrally formed with the flexible substrate 80430 of the flex circuit80400.

FIG. 80 depicts an end effector flex circuit 80500 configured to extendwithin an end effector. The end effector flex circuit 80500 isconfigured to be used with a shaft flex circuit, such as, for example,the flex circuit 80400 shown in FIGS. 79-79C. The end effector flexcircuit 80500 comprises electrical traces 80505 supported on a flexiblesubstrate. A distal end 80503 of the end effector flex circuit 80500 iswrapped into a ring 80504. The electrical traces 80505 extend around thering 80504. As shown in FIGS. 81A and 81B, the ring 80504 is configuredto be electrically coupled with the shaft flex circuit, for example, viathe first ring 80402 on the distal end 80401 of the flex circuit 80400.One or both of the flex circuits 80400 and 80500 comprise biasingmembers to maintain electrical contact between the traces at theinterface between the flex circuits 80400, 80500. In various instances,the end effector flex circuit 80500 comprises one or more sensors, suchas, for example, a clip feed sensor 80510 and/or a clip cam form sensor80520. Such sensors can detect a parameter of the end effector andcommunicate the detected parameter to the control circuit components80432, 80434, 80436 on the shaft flex circuit 80400. In variousinstances, the control circuit is positioned within a handle of thesurgical instrument.

Referring to FIG. 82, a surgical instrument 215000 comprises a handle215100, a shaft assembly 215500 attached to the handle 215100, an endeffector 215600, and an articulation joint 215550 rotatably connectingthe end effector 215600 to the shaft assembly 215500. The handle 215100includes a drive system 215200, a power supply 215300, and an actuator215400. The actuator 215400 is part of a closure drive configured toclose the end effector 215600. Referring to FIG. 83, the drive system215200 comprises a first drive motor 215210, a first shifter motor215220, a second drive motor 215250, and a second shifter motor 215260.The first drive motor 215210 comprises a rotatable input shaft and aninput gear 215215 fixedly mounted to the rotatable input shaft. Thefirst shifter motor 215220 comprises a shifter shaft and a pinion gear215225 rotatably mounted to the shifter shaft. The pinion gear 215225 isoperably intermeshed with the input gear 215215 of the first drive motor215210 and is translatable between first and second positions by thefirst shifter motor 215220. When the pinion gear 215225 is in its firstposition, the pinion gear 215225 is operably intermeshed with the inputgear 215215 and an output gear 215235 fixedly mounted to a rotatableoutput shaft 215230. In such instances, the rotation of the first drivemotor 215210 is transferred to the rotatable output shaft 215230 whenthe first drive motor 215210 is operated. When the pinion gear 215225 isin its second position, the pinion gear 215225 is operably intermeshedwith the input gear 215215 and an output gear 215245 fixedly mounted toa rotatable output shaft 215240. In such instances, the rotation of thefirst drive motor 215210 is transferred to the rotatable output shaft215240 when the first drive motor 215210 is operated. Notably, thepinion gear 215225 is not engaged with the output gears 215235 and215245 at the same time and, as a result, the first drive motor 215210can be used to drive two separate functions of the surgical instrument215000. In use, a user of the surgical instrument 215000, and/or acontrol system of the surgical instrument 215000, can select between thetwo functions by shifting the first shifter motor 215220.

Further to the above, the second drive motor 215250 comprises arotatable input shaft and an input gear 215255 fixedly mounted to therotatable input shaft. The second shifter motor 215260 comprises ashifter shaft and a pinion gear 215265 rotatably mounted to the shiftershaft. The pinion gear 215265 is operably intermeshed with the inputgear 215255 of the second drive motor 215250 and is translatable betweenfirst and second positions by the second shifter motor 215260. When thepinion gear 215265 is in its first position, the pinion gear 215265 isoperably intermeshed with the input gear 215255 and an output gear215275 fixedly mounted to a rotatable output shaft 215270. In suchinstances, the rotation of the second drive motor 215250 is transferredto the rotatable output shaft 215270 when the second drive motor 215250is operated. When the pinion gear 215265 is in its second position, thepinion gear 215265 is operably intermeshed with the input gear 215255and an output gear 215285 fixedly mounted to a rotatable output shaft215280. In such instances, the rotation of the second drive motor 215250is transferred to the rotatable output shaft 215280 when the seconddrive motor 215250 is operated. Notably, the pinion gear 215265 is notengaged with the output gears 215275 and 215285 at the same time and, asa result, the second drive motor 215250 can be used to drive twoseparate functions of the surgical instrument 215000. In use, a user ofthe surgical instrument 215000, and/or a control system of the surgicalinstrument 215000, can select between the two functions by shifting thesecond shifter motor 215260.

Further to the above, referring again to FIG. 83, the output shafts215230, 215240, and 215280 comprise rigid shafts and are concentricallynested. In various instances, a bearing is present between the outputshaft 215230 and the output shaft 215240 and another bearing is presentbetween the output shaft 215240 and the output shaft 215280. In otherinstances, the output shafts 215230, 215240, and 215280 are directlysupported by one another. Such arrangements can provide a compactdesign. In various alternative embodiments, none of the output shafts215230, 215240, and 215280 are nested.

Referring to FIG. 84, an alternative drive system 216200 is configuredto drive a total of six functions of a surgical instrument. Similar tothe above, the drive system 216200 comprises a first drive motor 216210,a first shifter motor 216220, a second drive motor 216250, and a secondshifter motor 216260. The first drive motor 216210 comprises a rotatableinput shaft and an input gear 216215 fixedly mounted to the rotatableinput shaft. The first shifter motor 216220 comprises a shifter shaftand a pinion gear 216225 rotatably mounted to the shifter shaft. Thepinion gear 216225 is operably intermeshed with the input gear 216215 ofthe first drive motor 216210 and is translatable between first, second,and third positions by the first shifter motor 216220. When the piniongear 216225 is in its first position, the pinion gear 216225 is operablyintermeshed with the input gear 216215 and an output gear 216235 fixedlymounted to a rotatable output shaft 216230. In such instances, therotation of the first drive motor 216210 is transferred to the rotatableoutput shaft 216230 when the first drive motor 216210 is operated. Whenthe pinion gear 216225 is in its second position, the pinion gear 216225is operably intermeshed with the input gear 216215 and an output gear216245 fixedly mounted to a rotatable output shaft 216240. In suchinstances, the rotation of the first drive motor 216210 is transferredto the rotatable output shaft 216240 when the first drive motor 216210is operated. When the pinion gear 216225 is in its third position, thepinion gear 216225 is operably intermeshed with the input gear 216215and an output gear 216295 fixedly mounted to a rotatable output shaft216290. In such instances, the rotation of the first drive motor 216210is transferred to the rotatable output shaft 216290 when the first drivemotor 216210 is operated. Notably, the pinion gear 216225 is not engagedwith more than one output gear 216235, 216245, and 216295 at a time and,as a result, the first drive motor 216210 can be used to drive threeseparate functions of the surgical instrument. In use, a user of thesurgical instrument, and/or a control system of the surgical instrument,can select between the three functions by shifting the first shiftermotor 216220.

Further to the above, the output shaft 216230 is operably engaged with ashaft 216500 of the surgical instrument such that the rotation of theoutput shaft 216230 is transferred to the shaft 216500. Morespecifically, the distal end of the output shaft 216230 comprises a gearintermeshed with a ring of gear teeth 216515 defined on the interior ofthe shaft housing 216510. The output shaft 216230 is rotated in a firstdirection to rotate the shaft 216500 in one direction and an oppositedirection to rotate the shaft 216500 in another direction. The outputshaft 216240 comprises a flexible cable which can be operably coupledwith a jaw clamping drive, a firing drive system, such as a staplefiring drive and/or a tissue cutting drive, for example, and/or an endeffector rotation drive, for example. The output shaft 216290 isoperably engaged with a first articulation drive 216700. The firstarticulation drive 216700 comprises two translatable articulationdrivers 216790, each of which is coupled to a translatable drive nut216795 threadably engaged with the output shaft 216290. Each drive nut216795 comprises a pin, or projection, extending into a groove definedin the output shaft 216290 and is constrained from rotating such thatthe rotation of the output shaft 216290 translates the drive nuts216795. In use, the output shaft 216290 is rotated in a first directionto rotate an end effector of the surgical instrument about a firstarticulation joint in one direction and rotated in an opposite directionto rotate the end effector about the first articulation joint in anotherdirection. The thread defined in the output shaft 216290 is configuredto push one of the drive nuts 216795 and articulation drivers 216790distally while it pulls the other drive nut 216795 and articulationdriver 216790 proximally. That said, one drive nut and articulationdriver 216795 can be sufficient to articulate the end effector about thefirst articulation joint.

Further to the above, the second drive motor 216250 comprises arotatable input shaft and an input gear 216255 fixedly mounted to therotatable input shaft. The second shifter motor 216260 comprises ashifter shaft and a pinion gear 216265 rotatably mounted to the shiftershaft. The pinion gear 216265 is operably intermeshed with the inputgear 216255 of the second drive motor 216260 and is translatable betweenfirst, second, and third positions by the second shifter motor 216260.When the pinion gear 215665 is in its first position, the pinion gear216265 is operably intermeshed with the input gear 216255 and an outputgear 215675 fixedly mounted to a rotatable output shaft 216270. In suchinstances, the rotation of the second drive motor 216250 is transferredto the rotatable output shaft 216270. When the pinion gear 216265 is inits second position, the pinion gear 216265 is operably intermeshed withthe input gear 216255 and an output gear 216285 fixedly mounted to arotatable output shaft 216280. In such instances, the rotation of thesecond drive motor 216250 is transferred to the rotatable output shaft216280. When the pinion gear 216265 is in its third position, the piniongear 216265 is operably intermeshed with the input gear 216215 and anoutput gear 216295′ fixedly mounted to a rotatable output shaft 216290′.In such instances, the rotation of the second drive motor 216250 istransferred to the rotatable output shaft 216290′. Notably, the piniongear 216265 is not engaged with more than one output gear 216275,216285, and 216295′ at a time and, as a result, the second drive motor216250 can be used to drive three separate functions of the surgicalinstrument. In use, a user of the surgical instrument, and/or a controlsystem of the surgical instrument, can select between the threefunctions by shifting the second shifter motor 216260.

Further to the above, the output shaft 216270 and/or the output shaft216280 can be operably coupled with a jaw clamping drive, a firing drivesystem, such as a staple firing drive and/or a tissue cutting drive, forexample, and/or an end effector rotation drive, for example. The outputshaft 216290′ is operably engaged with a second articulation drive216800. The second articulation drive 216800 comprises two translatablearticulation drivers 216890, each of which is coupled to a translatabledrive nut 216895 threadably engaged with the output shaft 216290′. Eachdrive nut 216895 comprises a pin, or projection, extending into a threador groove defined in the output shaft 216290′ and is constrained fromrotating such that the rotation of the output shaft 216290′ displacesthe drive nuts 216895. In use, the output shaft 216290′ is rotated in afirst direction to rotate an end effector of the surgical instrumentabout a second articulation joint in one direction and rotated in anopposite direction to rotate the end effector about the secondarticulation joint in another direction. The thread defined in theoutput shaft 216290′ is configured to push one of the drive nuts 216895and articulation drivers 216890 distally while it pulls the other drivenut 216895 and articulation driver 216890 proximally. That said, onedrive nut and articulation driver 216895 can be sufficient to articulatethe end effector about the second articulation joint.

As outlined above, the first drive motor 216210 and the first shiftermotor 216220 are configured to drive only one of their three functionsat a time. Similarly, the second drive motor 216250 and the secondshifter motor 216260 are configured to drive only one of their threefunctions at a time. That said, the drive system 216200 is configured tooperate the first drive motor 216210 and the second drive motor 216250at the same time such that the surgical instrument can perform twofunctions simultaneously. For instance, the first drive motor 216210 canarticulate the end effector about the first articulation joint via thedrive shaft 216290 while the second drive motor 216250 can articulatethe end effector about the second articulation joint via the drive shaft216290′. Similarly, the first drive motor 216210 can rotate the shaft216500 about a longitudinal axis while the second drive motor 216250rotates the end effector about a longitudinal axis. In some instances,however, the control system of the drive system 216200 can be configuredto prevent two end effector functions from being performed at the sametime. In at least one such instance, the control system is configured toprevent the end effector from being opened while a staple firing strokeis being performed.

Further to the above, the first shifter motor 216220 can be configuredto lock out the two non-coupled drive shafts when it operably couples adrive shaft with the first drive motor 216210. In at least one suchinstance, the translatable shaft of the first shifter motor 216220 cancomprise locks defined thereon which are configured to engage and lockthe two non-coupled drive shafts in position. In at least one instance,the first shifter motor 216220 locks the drive shaft 216230 and 216240when it operably engages the first drive motor 216210 with the driveshaft 216290. Similarly, the second shifter motor 216260 can beconfigured to lock out the two non-coupled drive shafts when it operablycouples a drive shaft with the second drive motor 216250. In at leastone such instance, the translatable shaft of the second shifter motor216260 comprises locks defined thereon which are configured to engageand lock the two non-coupled drive shafts in position. In at least oneinstance, the second shifter motor 216260 locks the drive shaft 216270and 216280 when it operably engages the second drive motor 216250 withthe drive shaft 216290′. In such instances, the end effector functionsnot being driven are positively disabled, or locked out. That said,embodiments are envisioned in which the end effector functions do notneed to be locked out when they are not being used or coupled with adrive motor. In any event, the first shifter motor 216220 and/or thesecond shifter motor 216260 can comprise a solenoid, for example, tocreate the longitudinal displacement of their shafts.

As outlined above, the drive system 215200 is configured to drive fourinstrument functions and the drive system 216200 is configured to drivesix instrument functions. That said, a drive system for the instrumentsdisclosed herein can be configured to drive any suitable number offunctions, such as more than six end effector functions, for example.

Further to the above, a motor control system of a surgical instrumentcan adapt the operation of one or more motors of the surgicalinstrument. Referring to FIG. 85, the surgical instrument 215000comprises a strain gage circuit 215900 which is in communication withthe motor control system of the surgical instrument 215000. The straingage circuit 215900 comprises a strain gage 215910 mounted to theshroud, or housing, 215510 of the shaft 215500. The strain gage 215910comprises a base 215920, a first electrical contact 215930 on the base215920, a circuitous electrical circuit 215940 in electricalcommunication with the first electrical contact 215930, and a secondelectrical contact 215950 in electrical communication with theelectrical circuit 215940. The electrical contacts 215930 and 215950 areconfigured to be soldered to, and/or otherwise electrically coupled to,conductive wires and/or traces, for example, to place the strain gage215910 in communication with the motor control system. The electricalcircuit 215940 is comprised of a thin conductive wire, the resistance ofwhich changes when the strain gage 215910 is stretched and/orcompressed, as discussed in greater detail below.

Referring again to FIG. 85, the base 215920 of the strain gage 215910 ismounted to the shroud 215510 such that the strain gage 215910 elongateswhen the shroud 215510 is placed in tension and contracts when theshroud 215510 is compressed. Referring to FIG. 85A, the resistance ofthe electrical circuit 215940 changes, i.e., increases, when the straingage 215910 is placed in tension along a longitudinal axis L, which isdetectable by the motor control system. Similarly, referring to FIG.85B, the resistance of the electrical circuit 215940 changes, i.e.,decreases, when the strain gage 215910 is compressed along thelongitudinal axis L, which is also detectable by the motor controlsystem. The change in resistance of the electrical circuit 215940 isproportional, or at least substantially proportional, to the strainbeing experienced by the shroud 215510 at the location of the straingage 215910. In various instances, an increase in strain in the shaftshroud 215510 can indicate that the patient tissue is beingover-stressed in some way. With this information, the motor controlsystem of the surgical instrument 215000 can alter the performance ofthe electric motors of the surgical instrument 215000. For instance,when the strain detected by the strain gage circuit exceeds apredetermined, or threshold, value stored in the memory and/or processorof the motor control system, for example, the motor control system canslow the motor, or motors, being operated at that time. In at least onesuch instance, the motor control system can slow the electric motordriving a staple firing stroke when the strain threshold is exceeded. Inother instances, the motor control system can slow an electric motordriving a clip forming stroke or an electric motor driving a suturestroke, for example, when the strain threshold is exceeded. In variousinstances, the motor control system can slow an electric motor closingor clamping an end effector and/or articulating the end effector, forexample.

Further to the above, the motor control system of the surgicalinstrument 215000 can adaptively control the speed of one or moreelectric motors. The motor control system comprises one or more pulsewidth modulation (PWM) circuits, and/or any other suitable power controlcircuit, for controlling the speed of the electric motors. A PWM circuitis configured to apply voltage pulses to an electric motor to drive theelectric motor at a desired speed—longer voltage pulses drive theelectric motor at a faster speed and shorter voltage pulses drive theelectric motor at a slower speed. In various instances, the motorcontrol system comprises one or more frequency modulation (FM) circuitsand/or voltage transformation circuits for controlling the speed of theelectric motors. A FM circuit can apply voltage pulses to a motor at ahigher frequency to drive an electric motor at a faster speed and/or alower frequency to drive an electric motor at a slower speed. PWMcircuits and FM circuits are configured to intermittently apply avoltage potential to an electric motor at a constant, or near constant,magnitude; however, various embodiments are envisioned in which themagnitude of the voltage potential can also be changed to adjust thepower delivered by the electric motor. Variable resistance circuits, forexample, can be used to change the magnitude of the voltage applied toan electric motor.

In addition to or in lieu of adapting the voltage delivered to theelectric motors of the surgical instrument 215000 to control the speedof the motors, the current delivered to the electric motors can beadapted to control the drive force delivered by the electric motors. Tothis end, a surgical instrument can include one or more motor currentcontrol circuits.

The strain gage 215910 is an axial strain gage which is well-suited tomeasuring strain along longitudinal axis L; however, one strain gage215910 may not provide a complete understanding of the strain occurringwithin the shroud 215510. Additional strain gages positioned adjacentthe strain gage 215910 which are oriented at different directions canprovide additional data regarding the strain occurring at that position.For instance, another strain gage can be positioned orthogonally to thestrain gage 215910 along the transverse axis T and/or at a 45 degreeangle relative to the longitudinal axis L, for example. Variousembodiments are envisioned in which the more than one strain gage isprovided on a single strain gage base. Such an arrangement can provide ahigher resolution of the strain at a particular location. The abovebeing said, any suitable strain gage can be used. For instance,capacitive strain gages, semiconductor strain gages, nanoparticle straingages, and/or fiber optic strain gages, for example, could be used.

When one or more resistance strain gages are bonded to a surface tomeasure strain, as discussed above, the strain gages can be arranged ina Wheatstone bridge circuit, as illustrated in FIG. 85C. A Wheatstonebridge is a divided bridge circuit used for the measurement of static ordynamic electrical resistance. The output voltage of the Wheatstonebridge is often expressed in millivolts output per volt input. Referringto FIG. 85C, if R1, R2, R3, and R4 are equal, and a voltage, V_(IN), isapplied between points A and C, then the output between points B and Dwill show no potential difference. However, if R4 is changed to somevalue which does not equal R1, R2, and R3, the bridge will becomeunbalanced and a voltage will exist at the output terminals. In aG-bridge configuration, the variable strain sensor has resistance Rg,while the other arms are fixed value resistors.

A strain gage sensor, however, can occupy one, two, or four arms of theWheatstone bridge. The total strain, or output voltage of the circuit(V_(OUT)) is equivalent to the difference between the voltage dropacross R1 and R4, or Rg. The bridge is considered balanced whenR1/R2=Rg/R3 and, therefore, V_(OUT) equals zero. Any small change in theresistance of the sensing grid will throw the bridge out of balance,making it suitable for the detection of strain. When the bridge is setup so that Rg is the only active strain gage, a small change in Rg willresult in an output voltage from the bridge.

The number of active strain gages that should be connected to the bridgedepends on the application. For example, it may be useful to connectstrain gages that are on opposite sides of the surgical instrumenthousing or shroud, one in compression and the other in tension. In thisarrangement, the bridge output for the same strain is effectivelydoubled. In installations where all four of the arms of a Wheatstonebridge are connected to strain gages, temperature compensation isautomatic, as resistance change due to temperature variations will bethe same for all four arms of the Wheatstone bridge.

In a four-element Wheatstone bridge, further to the above, usually twogages are wired in compression and two in tension, but any suitablearrangement can be used. For example, if R1 and R3 are in tension(positive) and R2 and R4 are in compression (negative), then the outputwill be proportional to the sum of all the strains measured separately.For gages located on adjacent legs of the Wheatstone bridge, the bridgebecomes unbalanced in proportion to the difference in strain. For gageson opposite legs of the Wheatstone bridge, the bridge balances inproportion to the sum of the strains. Whether bending strain, axialstrain, shear strain, or torsional strain is being measured, the straingage arrangement will determine the relationship between the output andthe type of strain being measured. As shown in FIG. 85C, if a positivetensile strain occurs on gages R2 and R3, and a negative strain isexperienced by gages R1 and R4, the total output, V_(OUT), would be fourtimes the resistance of a single gage.

Other strain gage circuits can be used in addition to or in lieu of theWheatstone bridges discussed above. Constant current and/or constantvoltage arrangements could be used, for instance.

As outlined above, the data provided by the one or more strain gages tothe motor control system can be used to modify the operation of one ormore electric motors of the surgical instrument. In addition to or inlieu of slowing an electric motor down, the motor control system canstop an electric motor. In at least one instance, the motor controlsystem uses two or more strain thresholds in which the motor controlsystem slows the electric motor down when the measured strain exceeds afirst threshold but stops the electric motor when the measured strainexceeds a second, or higher, threshold. In certain instances, the motorcontrol system slows the electric motor down when the measured strainexceeds a first threshold and slows the electric motor down even furtherwhen the measured strain exceeds a second, or higher, threshold. Invarious instances, the motor control system can be configured to speedup an electric motor and/or restore the original speed of the electricmotor when the measured strain falls below one or more of the thresholdsit exceeded. In any event, the motor control system is configured toreceive additional data from an off-instrument surgical hub regardingdetermining the appropriate reaction to an elevated strain state.Moreover, the motor control system is configured to transmit data to thesurgical hub which can store and/or analyze the strain data and emit areturn signal regarding the appropriate reaction to an elevated strainstate. To this end, the surgical instrument 215000 comprises a wirelesssignal transmitter and a wireless signal receiver; however, hard-wiredembodiments are envisioned.

Further to the above, it should be understood that obtaining accuratestrain readings is important. That said, the environment surrounding thesurgical instrument 215000 can affect the accuracy of the strain gagereadings. Among other things, changes in the temperature of the straingage 215910 and/or the substrate underlying the strain gage 215190 canaffect the strain gage readings. To this end, the surgical instrument215000 can include a temperature control system for controlling thetemperature of the strain gage 215910. In use, the temperature controlsystem is configured to heat and/or cool the strain gage 215910 tocontrol the temperature of the strain gage 215910 relative to a desiredor predetermined temperature. In at least one embodiment, thetemperature control system comprises a resistive heating electricalcircuit to heat the strain gage 215190 and/or the substrate underlyingthe strain gage 215190. The temperature control system can include aworking fluid refrigeration circuit, such as a carbon dioxiderefrigeration circuit, for example, to cool the strain gage 215190and/or the substrate underlying the strain gage 215190. In order toassess the temperature, or temperature change, of a strain gage, thestrain gage can include a temperature sensor on the substrate of thestrain gage which is in signal communication with the motor controlsystem. Alternatively, a temperature sensor can be adjacent the straingage. In either event, the motor control system can use the data from atemperature sensor to operate the heating and/or cooling systemsdiscussed above. In addition to or in lieu of actively heating and/orcooling a strain gage, a motor control system can adjust or compensatefor the increase in temperature by adjusting the data from the straingage in view of the data received from the temperature sensor. In atleast one instance, the curve relating the voltage of the strain gage tothe strain experienced by the underlying substrate can be adjusted forchanges in the temperature of the strain gage.

In many instances, further to the above, measuring strain is anexcellent proxy for determining the forces that a surgical instrument isexperiencing. That said, such strain measurements do not directlymeasure such forces. In various embodiments, the surgical instrument215000 comprises one or more force sensors positioned adjacent to thestrain gage 215910 to directly measure the forces. In at least oneinstance, a force sensor comprises a spring element that is stretchedand/or contracted along an axis which is parallel to, or at leastsubstantially parallel to, the longitudinal axis of the strain gage215910. The force sensor is in communication with the motor controlsystem and, as a result, the motor control system can use both thestrain gage data and the force sensor data to adapt the operation of thesurgical instrument motors.

Further to the above, the strains and/or forces within the shaft shroud215510 of the surgical instrument 215500 are measurable to control theoperation of the surgical instrument 215500. In various instances,elevated strain and/or force readings in the shaft shroud 215510 suggestthat the shaft of the surgical instrument 215500 may be pressed againstthe tissue of the patient. To make the clinician aware of the forcebeing applied to the patient tissue, the surgical instrument 215500further comprises an indicator in communication with the control systemof the surgical instrument 215500 which is activated by the controlsystem when the strain measured by the strain gages and/or the forcemeasured by the force gages in the shaft shroud 215510 exceed athreshold level. The indicator can comprise a light configured to createvisible feedback, a speaker configured to create auditory feedback, avibratory motor configured to create tactile feedback, and/or an icon ona display screen, for example. In certain instances, the control systemcan reduce the speed of the motor, or motors, in the surgical instrument215500 when the strain threshold is exceeded. Controlling the electricmotors in this manner can prevent the surgical instrument 215500 fromover-deflecting and/or breaking, especially when a part of the surgicalinstrument 215500 is articulating and/or rotating, for example. In atleast one instance, the strain gages and/or force sensors can be placedon and/or in a circuit board within the surgical instrument 215500, suchas a flex circuit, for example. In such instances, as a result,excessive force loading and/or deflection within the circuitry,especially circuitry mounted to the housing of the surgical instrument,can be prevented. That said, the strains and/or forces within a movingcomponent, such as a rotatable shaft and/or translatable drive member,could also be measured. Such an arrangement allows the motor controlsystem to directly evaluate the strains and/or forces within the drivesystems of the surgical instrument 215500 and prevent the electricmotors and/or drive components from being overstressed.

The above being said, a surgical instrument can utilize a strain gage inany suitable location. In various instances, a strain gage circuit cancomprise a strain gage positioned on the jaw of an end effector. Amongother things, such a strain gage can detect the deflection of the jaw,especially when positioned at the distal end of the jaw. With such data,the motor control system can adapt the operation of the surgicalinstrument to accommodate for an over-flexed jaw, for example. In atleast one such instance, the motor control system can slow down theelectric motor used to drive a distally-movable tissue cutting knife,such as the knife of a surgical stapler, for example. In use, a jaw willdeflect elastically when tissue is captured between the jaws of the endeffector, but the jaw can sometimes deflect plastically or permanently.A strain gage positioned on the jaw will allow the motor control systemto detect that the jaw has been permanently damaged when the jaw isunclamped. If the permanent damage is above a threshold, the motorcontrol system can limit the functionality of the surgical instrument insome way and/or indicate to the user that the surgical instrument hasbecome damaged and/or indicate the degree of the damage.

Further to the above, a strain gage of a strain gage circuit can beplaced on the jaw of a surgical stapler that supports a staplecartridge. When the jaws of the surgical stapler are clamped, the straingage can detect the strain within the cartridge jaw which can reveal thedeflection of the jaw. Along these lines, the deflection of the jaw canreveal the distance between the jaws, or tissue gap. With thisinformation, the motor control system can assess the thickness of thetissue between the jaws and control the speed of the drive motor whichdrives the tissue cutting knife. For instance, the motor control systemcan slow down the drive motor when the tissue is thick and/or speed upthe drive motor when the tissue is thin. In addition to or in lieu ofthe above, a strain gage of a strain gage circuit can be placed on thetissue cutting knife. Such a strain gage can provide data relating tothe thickness and/or density of the tissue to the motor control system.Similar to the above, the motor control system can slow down the drivemotor when the tissue is dense and/or speed up the drive motor when thetissue is less dense, for example. Moreover, the motor control systemcan stop and/or pause the drive motor which closes the jaw of the endeffector when the measured strain has reached a threshold. In manyinstances, the fluid in the clamped tissue needs time to flow out of thetissue in the end effector after the end effector has been initiallyclamped and, if the strain falls back below the threshold, the motorcontrol system can be configured to re-start the closure drive motor tocompress the tissue a desired amount. Such a strain gage can be placedon one of the end effector jaws and/or the closure drive member, forexample.

The surgical instruments described herein are insertable into a patientthrough a trocar, such as the trocar 219900 illustrated in FIG. 82C. Atrocar can comprise a long shaft 219910 comprising a longitudinalaperture 219920 extending there through, a sharp distal end 219930configured to be pushed through an incision in the patient, and aproximal end 219940 comprising a sealable port or opening configured toreceive a surgical instrument S. In use, the surgical instrument ispassed through the sealable port, through the longitudinal aperture, andinto a body cavity of the patient. The sealable port comprises a sealconfigured to prevent, or at least reduce, the flow of insufflation gasfrom the patient body cavity through the trocar. The seal is configuredto bias itself into a closed, or an at least substantially closed,configuration. Even when a surgical instrument is extending through thesealable port, the seal is biased against the sides of the surgicalinstrument to create a sealed, or an at least substantially sealed,interface therebetween. In use, the trocar is orientable within theincision to permit the surgical instrument to be properly orientedwithin the body cavity. In various instances, the clinician using thesurgical instrument pushes or pulls the surgical instrument in a desireddirection to orient the surgical instrument and, in such instances, thesurgical instrument contacts the sidewalls of the longitudinal aperturewhich also orients the trocar.

In various instances, further to the above, the trocar applies forces tothe patient tissue when the trocar is oriented by the surgicalinstrument. Excessive forces can pinch, bruise, and/or otherwise damagethe tissue. To this end, a trocar can comprise one or more force sensorcircuits and/or one or more strain gage circuits configured andpositioned to detect the forces applied to the trocar by the surgicalinstrument. In various instances, a force sensor circuit is embedded ina flexible substrate, such as a ribbon, for example, positioned withinthe longitudinal aperture of the trocar. In at least one such instance,the flexible substrate extends around the inner circumference of thetrocar shaft and is attached to the trocar shaft by one or moreadhesives, for example. The force sensor circuit comprises one or moretransducers supported within the flexible substrate which are compressedby the surgical instrument when the surgical instrument is pushedagainst the trocar. A transducer, such as a piezoelectric transducer,for example, converts mechanical energy into electrical energy and, whenthe transducer is compressed between the surgical instrument and thesidewall of the trocar, the force sensor circuit generates a voltagepotential. The trocar further comprises a control system in electricaland/or signal communication with the force sensor circuits which isconfigured to detect the voltage potential, and the magnitude of thevoltage potential, created by the transducers in the force sensorcircuits.

Further to the above, the control system of the trocar uses an algorithmto determine whether the voltage potentials from the force sensorcircuits exceed one or more thresholds. The trocar further comprises atleast one haptic feedback generator, such as a light, a speaker, and/oran eccentric motor, for example, in communication with the controlsystem and, when a voltage potential form a force sensor circuit exceedsa predetermined threshold, the control system can actuate the hapticfeedback generator to indicate to the clinician that they may beapplying an excessive force to the trocar and the patient tissue via thesurgical instrument.

Further to the above, the trocar can comprise a wireless signaltransmitter in communication with the control system of the trocar. Thewireless signal transmitter is configured to emit one or more signalsincluding data regarding the force sensor circuits, especially when athreshold has been exceeded. The surgical instrument inserted throughthe trocar can comprise a wireless signal receiver in communication withthe control system of the surgical instrument which is configured toreceive the wireless signals from the trocar and relay the signals, orthe data transmitted by the signals, to the instrument control system.The surgical instrument further comprises at least one haptic feedbackgenerator, such as a light, a speaker, and/or an eccentric motor, forexample, in communication with the instrument control system and, when avoltage potential from a force sensor circuit exceeds a predeterminedthreshold, the instrument control system can actuate the haptic feedbackgenerator to indicate to the clinician that they may be applying anexcessive force to the trocar and the patient tissue via the surgicalinstrument.

Further to the above, the trocar and surgical instrument can be part ofa surgical hub system. In various instances, the trocar and the surgicalinstrument communicate with the surgical hub system instead ofcommunicating directly, as discussed above.

The force sensor circuits of the trocar can be used to assess otherinformation regarding the surgical instrument. In at least one instance,the trocar control system can determine that a surgical instrument ispresent in the trocar when the voltage potential of one or more forcesensor circuits changes. In various instances, the trocar control systemcan determine the direction in which the surgical instrument is beingpushed. When the force sensor circuits on one lateral side of the trocarchange voltage potential and the force sensor circuits on the oppositelateral side of the trocar do not change voltage potential, or have alesser voltage potential change, the trocar control system can determinethe direction in which the surgical instrument is being pushed. Incertain instances, the trocar can comprise a proximal set of transducersand a distal set of transducers which can be used to assess theorientation of the surgical instrument in the trocar. When the proximaltransducers on a first lateral side of the trocar have a higher voltagepotential than the proximal transducers on a second, or opposite, sideof the trocar and the distal transducers on the second side have ahigher voltage potential than the distal transducers on the first side,the trocar control system can determine that the surgical instrument isoriented in the second direction within the patient, for example. Suchproximal and distal transducers can also be used to assess the torquethat the surgical instrument is applying to the trocar and/or patienttissue.

Further to the above, circuits within the trocar and circuits within thesurgical instrument can be inductively coupled. In various instances,one or more trocar circuits comprise windings extending around thetrocar shaft which generate a field within the trocar which interactswith one or more circuits in the surgical instrument. In at least onesuch instance, the trocar circuits comprise copper wires embedded in thetrocar housing, for example, and the surgical instrument circuitscomprise copper wires extending through the shaft of the surgicalinstrument. In such instances, the trocar can transmit power to thesurgical instrument and/or wireless data signals to the surgicalinstrument via this inductive coupling. The trocar can have its ownpower supply and/or can receive power from the surgical hub system inthe operating room. Alternatively, the circuits of the surgicalinstrument can be configured and arranged to communicate electricalpower and/or wireless signal data to the trocar. In such instances, thesensors, control system, and/or haptic feedback generators can bepowered by the surgical instrument positioned in the trocar. In certaininstances, the trocar can enter into a low power, or sleep, mode afternot being used for a predetermined period of time. The insertion of asurgical instrument into the trocar can be detected by the trocarcontrol system via these inductive circuits which can cause the trocarto enter a full power, or wake, mode. The insertion of a surgicalinstrument into the trocar can be detected by the instrument controlsystem via these inductive circuits which can cause the instrument toenter a full power, or wake, mode.

In any event, the above-provided discussion regarding the interactionbetween a trocar and a surgical instrument is applicable to bothhand-held surgical instruments and/or surgical instruments operated by arobotic surgical system.

Referring to FIG. 86, the surgical instrument 215000 comprises a motorcontrol system 215700. The motor control system 215700 comprises a firstcircuit board, i.e., flex circuit 215710, and, as described in greaterdetail below, a second circuit board, i.e., printed circuit board (PCB)215720. The flex circuit 215710 comprises a flexible substrate includinga non-conductive flexible base and conductive electrical traces definedwithin and/or on the non-conductive flexible base. The flex circuit215710 is contourable and is contoured to fit against the interiorsurface of the handle housing 215110. The interior surface of the handlehousing 215110 is generally concave and the flex circuit 215710 has beenflexed to match the concave configuration of the handle housing 215110;however, that said, the flex circuit 215710 is contourable to fit anysuitable configuration within the handle 215100.

The flexible base is comprised of polyimide and/or polyetheretherketone(PEEK), for example, and can comprise any suitable number of layers. Theconductive traces are comprised of copper, silver, and/or conductivepolyester, for example. The conductive traces are positioned between thelayers of the flexible base and/or embedded within the flexible base andare exposed at specific, pre-determined locations on the flex circuit215710. The exposed portions of the conductive traces are at leastpartially covered with a solder coating, such as tin and/or silver, forexample, and/or a flux coating, such as an organic flux, for example.The flex circuit 215710 further comprises electronic components mountedto the surface thereof. These surface mount electronic components aremechanically and electrically attached to the exposed portions of theconductive traces of the flex circuit 215710 via soldered connections.Surface mount electronics can be quickly assembled to the flex circuit215710 using a reflow soldering process, for example. In addition to orin lieu of the surface mount components, the flex circuit 215710 caninclude electronic components which have through-hole electricalcontacts. In such instances, the conductive traces include openings orthrough-holes which are configured to receive the electrical contacts orpins extending from the electronic devices. These pins can be solderedto the conductive traces using a reflow soldering process and/or a wavesoldering process, for example. In addition to the soldered electricalconnections, electronic components can be mechanically attached to theflexible base to reduce the possibility of the soldered connectionsbeing over-stressed.

Further to the above, the flex circuit 215710 is mounted to the handlehousing 215110 using one or more adhesives such that the bottom surfaceof the flex circuit 215710 is conformed to the handle housing 215110.The flex circuit 215710 can also be at least partially embedded in thehandle housing 215110. In at least one such instance, the handle housing215110 is comprised of plastic which is injection molded over at least aportion of the flex circuit 215710. In certain instances, conductivetraces can be directly attached to and/or embedded in the handle housing215110 without a flexible circuit board. For instance, conductive traces215760 are defined on the handle housing 215510 which are in electricalcommunication with electric contacts 215160. When the sides of thehandle housing 215110 are assembled together, the electrical contacts215160 on one side of the handle housing 215110 are electricallyconnected to corresponding electrical contacts on the other side. In anyevent, the conductive traces have portions thereof that are exposed suchthat electrical connections to the conductive traces can be made.

In use, further to the above, the power source 215300 supplies power tothe motor control system 215700. The power source 215300 comprises oneor more direct current (DC) batteries, but can comprise any suitablepower source such as an alternating current (AC) power source, forexample. The power source 215300 can comprise a voltage transformationcircuit to provide a desired voltage potential to the motor controlsystem 215700 via electrical wires, or conductors, 215750. Notably, theconductors 215750 are connected to a second circuit board 215720 of themotor control system 215700. The second circuit board 215720 comprises acard and is connected to the first circuit board 215710; however, thesecond circuit board 215720 can comprise any suitable configuration.Referring to FIG. 87, the second circuit board 215720 is insertable intoa card slot 215120 defined in the handle housing 215110. The card slot215120 is configured to securely receive the second circuit board 215720such that the second circuit board 215720 does not move, or at leastsubstantially move, relative to the handle housing 215110 once thesecond circuit board 215720 has been inserted therein. The card slot215120 comprises electrical contacts 215130 and 215140 mounted on thewalls thereof which are in communication with the flexible circuit board215710 via conductive traces 215150. When the second circuit board215720 is seated in the card slot 215120, the electrical contacts 215130and 215140 are electrically coupled to electrical contacts 215730 and215740 on the second circuit board 215720, respectively.

Further to the above, the second circuit board 215720 comprises a cardincluding a substrate and electronic components positioned on thesubstrate. The substrate includes a printed circuit board (PCB)comprising a plurality of rigid non-conductive layers and a plurality ofconductive traces positioned intermediate and/or on the non-conductivelayers. Owing to the rigidity of the second circuit board 215720, theconductive traces can be thick and/or wide which permits the traces tocarry large electrical power loads without overheating the materials ofthe second circuit board 215720. Similar to the above, the secondcircuit board 215720 comprises surface mount electronic componentsand/or through-hole-pin electronic components mounted to andelectrically coupled to the traces—both of which are designated aselectronic components 215725. As a result of the above, the secondcircuit board 215720 is well-suited to transmit electrical loads betweenthe power source 215300 and the electric motors of the surgicalinstrument 215000 which are often quite high. As such, the first circuitboard 215710 can comprise a flex circuit which can be thinner than a PCBand better suited to transmit lower electrical power loads. That said, aflex circuit can be designed to carry any suitable electrical powerloads and can be used for any suitable application in the surgicalinstrument 215000, for example.

In view of the above, the first circuit board 215710 is designed to havelow-power circuits and transmit lower electrical power loads than thesecond circuit board 215720 which is designed to have high-powercircuits. Low-power circuits include signal circuits and/or sensorcircuits, such as circuits which are responsive to inputs on the handle215100 and/or strain gage circuits, for example. High-power circuitsinclude motor control circuits which can comprise PWM and/or FM controlcircuits, for example. Other high-power circuits include aradio-frequency (RF) generator circuit and/or a transducer drive circuitconfigured to create a standing wave in an end effector, for example.

Further to the above, the first circuit board 215710 and/or the secondcircuit board 215720 comprise memory devices configured to store dataregarding the operation, state, and/or condition of the surgicalinstrument 215000, for example. Referring to FIGS. 82A and 82B, thefirst circuit board 215710 comprises at least one data access terminaland/or contact 215170 which can be used by a clinician to access thedata stored in the memory devices. To this end, the handle housing215110 comprises an access port 215180 configured to permit a connectorand/or probe 215880 to be inserted there through to operatively connectto the data access terminal 215170. The access port 215180 comprises aseal including an elastomeric portion comprised of rubber, for example,and a sealed, but openable, aperture extending through the elastomericportion. The aperture is biased closed, or at least substantiallyclosed, by the elastomeric material of the seal and is openable topermit the probe 215880 to be inserted therethrough. When the probe215880 is withdrawn from the access port 215180, the seal can re-sealitself.

In addition to or in lieu of the above, the handle housing 215110comprises a pierceable portion which is configured to be pierced by anelectrical probe, for example. The pierceable portion can comprise athinned portion of the handle housing 215110 which can be readilypierced by the electrical probe to access the circuit boards and/ormotor control system in the handle housing 215110. In at least oneinstance, the handle housing 215110 comprises a demarcation indicatingwhere the handle housing 215110 can be pierced. In at least oneinstance, the demarcation comprises a colored zone on the handle housing215110, for example.

Referring to FIGS. 88 and 89, a shaft assembly 215500′ is similar to theshaft assembly 215500 in many respects. Like the shaft assembly 215500,the shaft assembly 215500′ forms a rotatable interface with a handle,such as the handle 215100, for example, that allows the shaft assembly215500′ to rotate about a longitudinal axis. The shaft assembly 215500′comprises a flex circuit mounted to the interior of the shaft housing,or shroud, 215510′ which extends around the entire circumference of theshaft housing 215510′ and comprises annular electrical contacts 215520′.The handle comprises a motor control system 215700′ including a printedcircuit board (PCB) 215710′. The PCB 215710′ comprises electricalcontacts 215720′ which are engaged with and in electrical communicationwith the annular electrical contacts 215520′. Each electrical contact215720′ comprises a base seated in the PCB 215710′ and a compliant orspring member biased into engagement with an annular electrical contact215520′ such that the electrical contacts 215720′ are in electricalcommunication with the annular electrical contacts 215520′ regardless ofthe position in which the shaft assembly 215500′ is rotated relative tothe handle. The shaft assembly 215500′ further comprises wires orconductors 215530′ which place the electrical contacts 215520′ inelectrical communication with an electric motor 215200′. As a result ofthe above, the electric motor 215200′ in the shaft assembly 215500′ canbe powered by a power source in the handle. Moreover, the interfacebetween the electrical contacts 215520′ and 215720′ can transmit signalsbetween the shaft assembly 215500′ and the handle. Such an arrangementcan allow the motor control system in the handle to communicate with oneor more sensors, such as strain gauges and/or force sensors, forexample, in the shaft assembly 215500′, for instance.

Referring to FIG. 90, a handle 217100 is similar to the handle 215100 inmany respects. Among other things, the handle 217100 comprises a handlehousing 217110, a drive system comprising at least one electric motorand a motor control system, a removable battery 217300 configured tosupply power to the motor control system, and an actuation trigger217400 which, when actuated, closes an end effector of the shaftassembly attached to the handle 217100. In various instances, theelectric motor is configured to drive one end effector function, such asclosing the end effector, for example. To the extent that othermotorized functions are needed, in such instances, the handle 217100 caninclude other drive motors configured to drive those other end effectorfunctions. Alternatively, a drive motor can be used to drive more thanone end effector function, as described above.

Referring again to FIG. 90, the handle 217100 further comprises controls217140, 217150, and 217160 which are in communication with the motorcontrol system of the handle 217100. The control 217130 is actuatable tooperate an electric motor in the handle 217100 which articulates the endeffector with respect to a longitudinal axis of the shaft assemblyattached to the handle 217100. Referring to FIG. 92, the control 217130comprises a rocker button including a button shell 217132. The rockerbutton shell 217132 comprises a first shell portion 217131 and a secondshell portion 217133 which are separated by a recessed groove 217135defined in the rocker button shell 217132. The control 217130 furthercomprises a first strain gage circuit 217137 attached to and/or embeddedin the first shell portion 217131 and a second strain gage circuit217139 attached to and/or embedded in the second shell portion 217133.The first strain gage circuit 217137 and the second strain gage circuit217139 are in signal communication with the motor control system via oneor more wires or conductors 217136. The wall of the first shell portion217131 is configured to deflect and/or deform when a clinician depressesthe first shell portion 217131 and, in such instances, the motor controlsystem is configured to detect the change in resistance in the firststrain gage circuit 217137. Similarly, the wall of the second shellportion 217133 is configured to deflect and/or deform when a cliniciandepresses the second shell portion 217133 and, in such instances, themotor control system is configured to detect the change in resistance inthe second strain gage circuit 217139. When the motor control systemdetects an increase in resistance in the first strain gage circuit217137, the motor control system operates the articulation drive motorto articulate the end effector in a first direction. Correspondingly,the motor control system operates the articulation drive motor toarticulate the end effector in a second, or opposite, direction when themotor control system detects an increase in resistance in the secondstrain gage circuit 217139. When the clinician releases or removes theirhand from the control 217130, the button shell 217132 will resilientlyreturn to its original configuration and the resistance in the first andsecond strain gage circuits 217137 and 217139 returns to its originalstate. This change in the strain gage circuit resistance is detected bythe motor control system and, at that point, the motor control systemstops driving the articulation drive motor.

Further to the above, the control 217140 is also actuatable to operatethe articulation drive motor in the handle 217100. Referring to FIG. 91,the control 217140 comprises a push button including a button shell217142. The control 217140 further comprises a strain gage circuit217144 attached to and/or embedded in the button shell 217142. Thestrain gage circuit 217144 is in signal communication with the motorcontrol system via one or more wires or conductors 217146. The wall ofthe button shell 217142 is configured to deflect and/or deform when aclinician depresses the button shell 217142 and, in such instances, themotor control system is configured to detect the change in resistance inthe strain gage circuit 217144. When the motor control system detects anincrease in resistance in the strain gage circuit 217144, the motorcontrol system operates the articulation drive motor to align, of atleast substantially re-align, the end effector with the longitudinalaxis of the shaft assembly, i.e., move the end effector to a homeposition. To this end, the motor control system is configured to trackthe position of the end effector so as to know the direction and amountin which to articulate the end effector to move the end effector to itshome position. In at least one embodiment, the motor control systemcomprises an encoder, for example, to track the position of the endeffector. Once the end effector has been re-centered with thelongitudinal shaft axis, the motor control system will stop thearticulation drive motor. When the clinician releases or removes theirhand from the control 217140, the button shell 217142 will resilientlyreturn to its original configuration and the resistance in the straingage circuit 217144 will return to its original state.

Further to the above, the control 217150 is actuatable to operate afiring drive motor in the handle 217100 to perform, for example, astaple firing stroke, a clip crimping stroke, or a needle suturingstroke—depending on the type of shaft assembly attached to the handle217100. Referring to FIG. 93, the control 217150 is positioned on theclamping actuator 217400 and comprises a push button including a buttonshell 217152. The control 217150 further comprises a strain gage circuit217154 attached to and/or embedded in the button shell 217152. Thestrain gage circuit 217154 is in signal communication with the motorcontrol system via one or more wires or conductors 217156. The wall ofthe button shell 217152 is configured to deflect and/or deform when aclinician depresses the button shell 217152 and, in such instances, themotor control system is configured to detect the change in resistance inthe strain gage circuit 217154. When the motor control system detects anincrease in resistance in the strain gage circuit 217154, the motorcontrol system operates the firing drive motor to drive a firing memberdistally. To this end, the motor control system is configured to trackthe position of the firing member so as to know when the firing memberhas reached the end of tis firing stroke and stop the firing drivemotor. In at least one embodiment, the motor control system comprises anencoder, for example, to track the position of the firing member. Inaddition to the above, the motor control system is configured to stopthe firing drive motor when the clinician releases or removes their handfrom the control 217150. In such instances, similar to the above, thebutton shell 217152 resiliently returns to its original configurationand the resistance in the strain gage circuit 217154 returns to itsoriginal state, which is detected by the motor control system.

As discussed above, the controls 217130, 217140, and 217150 aredeformable to actuate a function of the surgical instrument. To theextent that the controls 217130, 217140, and 217150 are readilydeformable, they may experience large strains which are readilydetectable by their respective strain gage circuits. Referring to FIG.95, an actuator 217170 comprises a button shell 217172 which has one ormore living hinges 217174 defined in the walls of the button shell217172. Such living hinges 217174 can permit the button shell 217172 toreadily deform. Score marks in the button shell 217172 could also beused. In various instances, an actuator can comprise a feature whichcauses the housing of the actuator to suddenly flex, elastically snap,or give way when a force threshold has been exceeded. That said, suchreadily deformable controls may be accidentally actuated by theclinician. To this end, the motor control system can utilize one or moremeasured strain thresholds which can reduce the possibility of thesurgical instrument responding to incidental touches of the controls217130, 217140, and 217150. For instance, for strains measured by thestrain gage circuit 217144 of the actuator 217140 which are below athreshold, the motor control system will not actuate the articulationdrive motor. Correspondingly, the motor control system will actuate thearticulation drive motor for measured strains that meet or exceed thethreshold. The motor control system can also include measured strainthresholds for the other controls 217130 and 217150. The measured strainthresholds can be the same for each of the controls 217130, 217140, and217150 or they can be different. Given that different types of buttonscan deform differently, using different measured strain thresholds canbe advantageous.

Referring to FIG. 94, further to the above, an actuator 217160 comprisesa solid button shell 217162. Unlike the button shell 217172, the buttonshell 217162 is configured such that it does not significantly deformwhen it is actuated. As a result, the motor control system incommunication with the strain gage circuit of the actuator 217160 isconfigured to be responsive to much lower measured strain values. On theother hand, the actuator 217160 can be used to actuate an importantfunction of the surgical instrument and it may be desirable to have ahigh measured strain threshold to prevent the accidental actuation ofthe important function despite having a stiff button wall of theactuator 217160. In such instances, the clinician would have to make aconcerted effort to sufficiently depress the actuator 217160 to actuatethe important function.

When an actuator is easily deformable, further to the above, theclinician should be able to readily sense that they have actuated theactuator when the wall of the actuator gives way or elasticallycollapses. When an actuator is stiff, however, a clinician may not beable to intuitively sense that the actuator has been actuated. In eitherevent, a surgical instrument can include a haptic feedback generator incommunication with the motor control system. When the motor controlsystem determines that the measured strain in an actuator strain gagecircuit has exceeded the predetermined threshold, the motor controlsystem can activate the haptic feedback generator which can notify theclinician that the actuator has been sufficiently actuated. In variousinstances, the haptic generator comprises at least one visual indicatordevice, such as a light, for example, at least one auditory indicatordevice, such as a speaker, for example, and/or at least one vibratoryindicator device, such as an electric motor with an eccentric rotationalelement, for example.

In various embodiments, further to the above, a motor control system canutilize two or more measured strain thresholds in connection with anactuator, such as the actuator 217160, for example, for determining anappropriate action of the surgical instrument. For instance, the motorcontrol system can comprise a first measured strain threshold and asecond measured strain threshold which is higher than the first strainthreshold. When the measured strain is below the first measured strainthreshold and the second measured strain threshold, the motor controlsystem does not drive the electric motor of the drive system associatedwith the actuator. When the measured strain is at or above the firstmeasured strain threshold but below the second measured strainthreshold, the motor control system actuates a first haptic feedbackgenerator, such as a first light, for example, but it does not drive theelectric motor. When the measured strain is at or above the secondmeasured strain threshold, the motor control system actuates a secondhaptic feedback generator, such as a second light, for example, anddrives the electric motor. In such instances, the clinician is providedwith a warning or notice via the first haptic feedback generator thatthey are depressing the actuator in some way, intentionally orunintentionally. When the measured strain falls below the secondmeasured strain threshold, but not the first measured strain threshold,the motor control system deactivates the second haptic feedbackgenerator, but not the first haptic feedback generator. The motorcontrol system also stops driving the electric motor in such instances.When the measured strain falls below the first measured strainthreshold, the motor control system deactivates the first hapticfeedback generator.

Further to the above, the actuators 217130 and 217140 are comprised of adifferent material than the handle housing 217110. The actuators 217130and 217140 are comprised of a first plastic material and the handlehousing 217110 is comprised of a second plastic material which isdifferent than the first plastic material. The first plastic material ismore flexible than the second plastic material so that the actuators canbe deformed to actuate the surgical instrument, as described above. Invarious instances, the first plastic material is selected such that themodulus of elasticity of the first plastic material is lower than themodulus of elasticity of the second plastic material. In any event, theactuators 217130 and 217140 are manufactured separately from the handlehousing 217110 and then assembled to the handle housing 217110. Theactuators 217130 and 217140 and the handle housing 217110 compriseco-operating features which interlock to connect the actuators 217130and 217140 to the handle housing 217110. In at least one embodiment, theactuators 217130 and 217140 are placed in a mold and the handle housing217110 is injection molded around the actuators 217130 and 217140 suchthat the button housings are held in place, yet sufficiently exposedsuch that the clinician can actuate them. Similar to the above,interlocking features between the actuators 217130 and 217140 and thehandle housing 217110 can be created during the injection moldingprocess which hold the actuators 217130 and 217140 in position relativeto the handle housing 217110. In various instances, the actuators 217130and 217140 are formed during a first shot of an injection moldingprocess and the handle housing 217110 is formed during a second shot ofthe injection molding process. These arrangements can decrease, if noteliminate, the size of the seam openings between the actuators 217130and 217140 and the handle housing 217110. The above-provided discussionalso applies to the closure actuator 217400 and the actuator 217150which, once manufactured, can be assembled to the handle housing 217110.

In various alternative embodiments, further to the above, the actuators217130 and 217140 are comprised of the same material as the handlehousing 217110. In at least one such embodiment, the actuators 217130and 217140 are thinner than the handle housing 217110 such that they cansufficiently deform to actuate the surgical instrument while the handlehousing 217110 is sufficiently rigid so as to not deform unacceptablyduring use. Similar to the above, the actuators 217130 and 217140 can bemanufactured separately from the handle housing 217110 and thenassembled to the handle housing 217110. In at least one alternativeembodiment, the actuators 217130 and 217140 are formed integrally withthe handle housing 217110. In such instances, the handle housing 217110can be formed in two halves which are assembled together by a snap-fitconnection, fasteners, and/or one or more adhesives, for example. In atleast one embodiment, the actuators 217130 and 217140 and the handlehousing 217110 are formed during an injection molding process. In suchinstances, the strain gage circuits 217134 and 217144 can be positionedin the mold before the melted plastic is injected into the mold suchthat the strain gage circuits 217134 and 217144 are at least partiallyembedded in the actuators 217130 and 217140. Otherwise, the strain gagecircuits 217134 and 217144 can be applied to the actuators 217130 and217140, respectively, after the injection molding process. Similar tothe above, the actuators 217130 and 217140 are thinner than the handlehousing 217110 such that they can sufficiently deform to actuate thesurgical instrument while the handle housing 217110 is sufficientlyrigid so as to not deform unacceptably during use. Such arrangements caneliminate the seams between the actuators 217130 and 217140 and thehandle housing 217110 and create a sealed interface between theactuators 217130 and 217140 and the handle housing 217110. Theabove-provided discussion also applies to the closure actuator 217400and the actuator 217150 which, once manufactured, can be assembled tothe handle housing 217110.

In various instances, the plastics used to form the actuators 217130 and217140 and/or the handle housing 217110 are capable of beingelectroplated. In at least one such instance, conductive traces areelectroplated directly onto the actuators 217130 and 217140 and/or thehandle housing 217110. The electroplated conductive traces can becomprised of any suitable material, such as tin and/or silver, forexample.

In various embodiments, sensors and/or switches other than strain gagescan be used to actuate the electric motors of a motor control system. Inat least one such embodiment, a handle and/or shaft of a surgicalinstrument comprises at least one actuator which is deflectable tocontact a sensor and/or switch to open and/or close a sensor circuit, asthe case may be, to actuate an electric motor of the surgicalinstrument. Similar to the above, such an actuator can comprise aseparate component which is assembled to the handle housing, forexample, and is deformable inwardly to contact a sensor and/or switch.Also similar to the above, such an actuator can comprise an integralthin portion of the handle housing which is deformable inwardly tocontact a sensor and/or switch. In either event, the sensor and/orswitch is positioned behind and aligned with the actuator and can bemounted to a circuit board, for example.

Referring again to FIG. 82, the shaft assembly 215500 comprisesactuators 215520, 215530, and 215540 which are configured to operate inthe same or similar way as the other actuators described herein. Theactuators of the shaft assembly 215500 comprise slide rail actuators,radial actuators, rotational actuators, press-button actuators, and/orany other suitable actuators. In various instances, the shaft assembly215500 is not meant to be re-used after the surgical procedure and is,thus, disposable. In certain instances, the shaft assembly 215500 can bere-used if it has not exceeded its maximum number of permittedactuations and has been cleaned and re-sterilized. The handle 215100 canalso be disposable or re-usable.

In various alternative embodiments, an actuator can be actuated withouthaving to be deflected and/or deformed. In at least one such embodiment,the actuator comprises a capacitive sensor circuit attached to and/orembedded within the handle housing which is in signal communication withthe motor control system. The capacitive sensor circuit comprises one ormore capacitive sensors which are evaluated by the motor control systemfor changes in capacitance therein when the clinician places theirfinger on and/or over one of the capacitive sensors. When the measuredcapacitance, or capacitance change, exceeds a predetermined threshold,the motor control system actuates the electric motor of the drive systemassociated with the actuator. When the measured capacitance, orcapacitance change, falls below the predetermined threshold, the motorcontrol system no longer drives the electric motor. That said, the motorcontrol system can be configured to perform any suitable action when themeasured capacitance, or capacitance change, falls below thepredetermined threshold.

In at least one instance, further to the above, the handle housingcomprises recesses defined therein and the capacitive sensors arepositioned in the recesses. Such an arrangement allows the capacitivesensors to be flush, or at least substantially flush, with the outersurface of the handle housing. In at least one such instance, thecapacitive sensors can be a different color than the handle housing suchthat they are readily observable by the clinician.

In various instances, further to the above, an actuator comprises amembrane switch. In at least one instance, a membrane switch comprisestwo conductive plates separated by dielectric dots positioned betweenthe conductive plates. One or both of the conductive plates areconfigured to flex when the membrane switch is depressed and change theelectrical state of the membrane switch. The membrane switch can behermetically sealed so as to prevent water intrusion and/or contaminantsfrom entering the membrane switch which can unintentionally change theelectrical properties of the membrane switch.

Further to the above, an actuator can comprise a piezoelectric sensorcircuit attached to and/or embedded within the handle housing which isin signal communication with the motor control system. The piezoelectricsensor circuit comprises one or more piezoelectric sensors which areevaluated by the motor control system for changes in electricalproperties thereof when the clinician places their finger on and/or tapsone of the piezoelectric sensors. When the measured electrical property,or electrical property change, exceeds a predetermined threshold, themotor control system actuates the electric motor of the drive systemassociated with the actuator. When the measured electrical property, orelectrical property change, falls below the predetermined threshold, themotor control system no longer drives the electric motor. That said, themotor control system can be configured to perform any suitable actionwhen the measured electrical property, or electrical property change,falls below the predetermined threshold. In at least one instance, thehandle housing comprises recesses defined therein and the piezoelectricsensors are positioned in the recesses. Such an arrangement allows thepiezoelectric sensors to be flush, or at least substantially flush, withthe outer surface of the handle housing. In at least one such instance,the piezoelectric sensors can be a different color than the handlehousing such that they are readily observable by the clinician.

Referring to FIG. 96, a handle 218100 comprises a handle housing 218110,a button actuator 218140, a rotatable actuator 218400, and apositionable actuator 218800. The positionable actuator 218800 comprisesan arm 218810 which is rotatably mounted to the handle housing 218110about a pivot pin 218820 which defines a rotation axis RA. The pivot pin218820 is secured to the housing 218110 such that the positionableactuator 218800 does not translate, or at least substantially translate,relative to the housing 218110. Moreover, the pivot pin 218820 fitssnugly in an aperture in the housing 218110 such that rotating the arm218810 about the rotation axis RA requires a concerted effort on thepart of the clinician. In at least one instance, the pivot pin 218820comprises a lock screw which is loosenable to pivot the arm 218810 andtightenable to lock the arm 218810 in position. In any event, the arm218810 can be pivoted into a comfortable position for the clinician suchthat a joystick 218830 on the arm 218810 is easily accessible by theclinician. The joystick 218830 comprises one or more sensors incommunication with the motor control system of the handle 218100. Inuse, the motor control system is configured to interpret and usevoltages, currents, and/or any other data from the sensors of thejoystick 218830 to articulate the end effector of a shaft assemblyattached to the handle 218100. The end effector is articulatable in morethan one plane and can be articulatable about one or more articulatejoints by one or more motor-driven articulation drive systems.

Referring to FIG. 97, a handle 218100′ comprises a handle housing218110′, a button actuator 218140, a rotatable actuator 218400, and apositionable actuator 218800′. The positionable actuator 218800′comprises an arm 218810′ which is rotatably mounted to the handlehousing 218110′ about a pivot pin 218820′ which defines a rotation axisRA. The pivot pin 218820′ is secured to the housing 218110′ such thatthe positionable actuator 218800′ does not translate, or at leastsubstantially translate, relative to the housing 218110′. Moreover, thepivot pin 218820′ fits snugly in an aperture in the housing 218110′ suchthat rotating the arm 218810′ about the rotation axis RA requires aconcerted effort on the part of the clinician. In at least one instance,the pivot pin 218820′ comprises a lock screw which is loosenable topivot the arm 218810′ and tightenable to lock the arm 218810′ inposition. In any event, the arm 218810′ can be pivoted into acomfortable position for the clinician such that a joystick 218830 onthe arm 218810′ is easily accessible by the clinician. For instance, thearm 218810′ is rotatable between the left and right sides of the handle218100′. The joystick 218830 comprises one or more sensors incommunication with the motor control system of the handle 218100′. Inuse, the motor control system is configured to interpret and usevoltages, currents, and/or any other data from the sensors of thejoystick 218830 to articulate the end effector of a shaft assemblyattached to the handle 218100′. The end effector is articulatable inmore than one plane and can be articulatable about one or morearticulate joints by one or more motor-driven articulation drivesystems.

Referring to FIG. 98, a surgical instrument handle 219100 comprises ahandle housing 219110, a button actuator 218140, and a joystick 219130.Unlike the joystick 218130, the joystick 219130 is not mounted on arotatable arm and is, instead, directly mounted to the handle housing219110. The joystick 219830 comprises one or more sensors incommunication with the motor control system of the handle 219100. Inuse, the motor control system is configured to interpret and usevoltages, currents, and/or any other data from the sensors of thejoystick 219830 to articulate the end effector of a shaft assemblyattached to the handle 219100. The end effector is articulatable in morethan one plane and can be articulatable about one or more articulatejoints by one or more motor-driven articulation drive systems.

In addition to or in lieu of a joystick for controlling the articulationof the end effector, a surgical instrument can include a projectedcapacitive (PCAP) touchscreen for controlling the articulation of theend effector. A PCAP touchscreen comprises electrodes that are alignedin a grid pattern on the sensor side of a touch panel. The electrodegrid detects the touch point by sensing the change of electrical chargesthat occur when a finger of the clinician touches the surface of thetouch panel. Such a device can be used in conjunction with amicroprocessor of a motor control system which is configured tointerpret the touches and/or touch motions on the PCAP touchscreen andmove the end effector in a manner which parallels the touches and/ortouch motions. The microprocessor is configured to interpret fingertaps, finger drags, and/or rotational finger swipes, for example, on thePCAP touchscreen and articulate the end effector in an intuitive manner.For instance, the microprocessor is configured to interpret a finger tapon the PCAP touchscreen as a command to position the end effector in alocation which corresponds to where the finger tap occurred on the PCAPtouchscreen. A finger tap on the left side of the PCAP touchscreen willcause the end effector to be articulated to the left and a finger tap onthe right side of the PCAP touchscreen will cause the end effector to bearticulated to the right, for example. A finger tap on the top side ofthe PCAP touchscreen will cause the end effector to pitch down and afinger tap on the bottom side of the PCAP touchscreen will cause the endeffector to pitch up. A finger drag on the PCAP touchscreen will causethe end effector to be articulated in the direction of the finger dragand at the speed of the finger drag, for example. A leftward motionarticulates the end effector left, a rightward motion articulates theend effector right, a topward motion pitches the end effector down, anda bottomward motion pitches the end effector up. A fast finger drag willarticulate the end effector quickly and a slow finger drag willarticulate the end effector slowly. A rotational finger swipe on thePCAP touchscreen will cause the end effector to rotate about alongitudinal axis in the direction of the rotational finger swipe, forexample. A clockwise finger swipe will rotate the end effector clockwiseand a counter-clockwise finger swipe will rotate the end effectorcounter-clockwise.

Further to the above, the PCAP touchscreen can include icons thereonwhich facilitate the use of the PCAP touchscreen and suggest how thefinger motions will be interpreted by the microprocessor. A finger tapicon is depicted in FIG. 99. A finger drag icon is depicted in FIG. 100.A rotational finger swipe is depicted in FIG. 101. Such icons could alsobe positioned on the handle housing.

A surgical theatre is often divided into a sterile field and anon-sterile field. During a surgical procedure, certain cliniciansremain in the sterile field while other clinicians remain in thenon-sterile field. Typically, surgical instruments within the sterilefield are handled by the clinicians in the sterile field. That said,instances are envisioned in which a surgical instrument comprises asterile barrier that allows a clinician, in the sterile field ornon-sterile field, to interact with the surgical instrument. In at leastone instance, the sterile barrier comprises a flexible membrane mountedto the surgical instrument. Depending on the surgical instrument and itsuse, the entirety of the surgical instrument or only a portion of thesurgical instrument is protected by the sterile barrier. In at least oneinstance, the surgical instrument comprises one or more pressuresensitive displays that can be interacted with through the sterilebarrier. In use, the surgical instrument in the sterile barrier maygenerate heat. To this end, the sterile barrier can comprise a heat sinkconfigured to extract heat from within the sterile barrier and dissipatethe heat into the surrounding environment. The heat sink can becomprised of any suitable thermally conductive material, such as copperand/or silver, for example. Silver provides an additional advantageowing to its anti-microbial properties. In at least one instance, theheat sink comprises an array of conductive traces extending within thesterile barrier. The conductive traces are embedded within, attached to,and/or printed on the sterile barrier. Such traces can promoteconductive heat transfer. In at least one instance, the conductivetraces comprise fins that extend from the sterile barrier. Such fins canpromote convective heat transfer. In various instances, the materials ofthe sterile barrier and/or conductive traces are comprised of a materialwhich promotes radiant heat transfer.

As discussed above, a surgical instrument can comprise two or morecircuit boards which are operably interconnected by one or moreelectrical connectors. In many instances, an electrical connectioncomprises two halves—a male connection half and a female connectionhalf. The male connection half comprises male electrical contacts whichcan comprise pins, for example, while the female connection halfcomprises female electrical contacts which can comprise sockets, forexample, configured to receive the pins. Each socket comprises one ormore deflectable members or tangs configured to engage a pin insertedinto the socket and establish one or more electrical contact interfacestherebetween. Even under ideal conditions, such electrical contactinterfaces create voltage drops within an electrical circuit. Moreover,an electrical contact interface can degrade over time and/or as a resultof use. For instance, the surfaces of the contact interface can oxidizeover time and, in such instances, the voltage drop across the contactinterface increases as the oxidization increases. In order to reducesuch oxidization, the pins and/or sockets can be electroplated with tin,lead, silver, and/or gold, for example. Such electroplating can compriseany suitable thickness, such as between approximately 5 μm andapproximately 100 μm, for example. Electroplating having a thickness ofapproximately 5 μm is often referred to as a “strike” of electroplatingand is often used when the plating material is expensive, such as gold,for example. A contact interface can degrade for other reasons,especially when the contact interface carries a high power load. Invarious instances, a contact interface can develop “whiskers” which growoutwardly from an electro-plated surface, especially when tin plating isused without lead intermixed therein. Such whiskers can reduce thedistance between adjacent pairs of electrical contacts and, as a result,increase the electromagnetic interference between the adjacent pairs ofelectrical contacts and/or create a short between the pairs ofelectrical contacts. That said, various metals can be introduced intothe electroplating to reduce the growth of such whiskers. In someinstances, a contact interface can develop fretting corrosion within thecontact interface as a result of thermocycling, for example. In certaininstances, one of the contact tangs can bend or yield when theelectrical connectors are engaged with one another.

In view of the above, a control circuit of a surgical instrumentcomprising one or more electrical interconnections can be configured toassess the contact quality of the electrical interconnections after thecomponents of the surgical instrument have been assembled togetherand/or during the use of the surgical instrument. The control circuit isconfigured to assess if the signal across an electrical connection isbeing distorted by the electrical connection. In at least one instance,the control circuit comprises a signal emitter configured to emit asignal through an electrical circuit including an electrical contact, asignal receiver configured to compare the return signal to the expectedreturn signal, and a digital signal processor for determining if thereis signal distortion. Any suitable algorithm can be used to assesssignal distortion, such as an algorithm that uses the root mean squareof the signal, for example. If the return signal for each of theelectrical circuits sufficiently matches their expected return signal,then the control circuit can communicate to the user of the surgicalinstrument that the signal fidelity within the surgical instrument issufficient. In at least one instance, the control circuit comprises anindicator light, such as an LED, for example, which is illuminated toindicate there is sufficient signal fidelity in the surgical instrument.If one or more of the return signals does not sufficiently match itsexpected return signal, the control circuit can communicate to the userof the surgical instrument that the signal fidelity within the surgicalinstrument may not be sufficient. In such instances, another LED couldbe illuminated and/or the signal fidelity LED can comprise a two-colorLED which can be switched from green to red, for example. In variousinstances, the control circuit is configured to use more than one signalfidelity threshold—a first threshold above which there is sufficientsignal fidelity (or an acceptable amount of noise), a second thresholdbelow the first threshold above which indicates possibly sufficientsignal fidelity (or a potentially inappropriate amount of noise), and athird threshold below the second threshold below which there isinsufficient signal fidelity (or extensive noise). When the signalfidelity of an electrical circuit is between the first and secondthresholds, the control circuit can increase the gain of the powersupplied to that circuit to improve the fidelity of the signal. In atleast one instance, the magnitude of the voltage is increased. Incertain instances, the control circuit can adjust the communicationspeed across an electrical circuit in view of the signal-noise ratio.For high signal-noise ratios, the control circuit can transmit dataacross the electrical contact interface at a high rate or with shortgaps between the data, or data packets, for example. For lowsignal-noise ratios, the control circuit can transmit data across theelectrical contact interface at a lower rate or with longer gaps betweenthe data, or data packets, for example.

In addition to or in lieu of the above, a control circuit is configuredto assess the voltage drop across an electrical contact interface. Forinstance, when the control circuit detects that a lower-than-expectedvoltage potential is being delivered to an electronic device within anelectrical circuit, for example, the control circuit can increase thegain of the power supplied to that electrical circuit. In at least onesuch instance, the magnitude of the voltage is increased, for example.To the extent that a short circuit is detected in an electrical circuit,the surgical instrument may be unusable altogether or limited in thefunctions that it can perform. To this end, the control circuit, aprocessing circuit and/or an algorithm can be utilized to decide whetheror not the short circuit is present on a critical function, whether thesurgical instrument can still be used, and what functions can still beused. Upon detecting a short circuit, in various instances, the controlcircuit can enter into a limp mode that permits only the surgicalinstrument functions that allow the surgical instrument to be removedfrom the patient and/or permits the status of the surgical instrument tobe monitored by the clinician, for example. In addition to or in lieu ofthe above, the control circuit can execute an algorithm for assessingwhether a detected short circuit is actually a short circuit. In atleast one instance, the algorithm operates to increase the gain of thesignal in the electrical circuit upon detecting a short circuit and, ifthe short circuit is still detected after increasing the gain, thecontrol circuit quickly interrupts the power to the electrical circuitcomprising the short circuit. However, if increasing the signal gainestablishes or re-establishes sufficient signal fidelity, then thecontrol circuit can continue to permit the use of that electricalcircuit.

Further to the above, the signal fidelity and/or voltage drop within anelectrical circuit can be assessed when the surgical instrumentcomponents are assembled. The electrical circuits can also be assessedwhen the surgical instrument is powered on and/or woken up from a lowpower, or sleep, mode. The electrical circuits can be assessedintermittently or continuously throughout the operation of the surgicalinstrument. In various instances, the control circuit of a surgicalinstrument can enter into a limp mode when the signal distortion and/orvoltage drop exceed a predetermined threshold. In various instances, thecontrol circuit can enter into a limp mode that permits only thesurgical instrument functions that allow the surgical instrument to beremoved from the patient and/or permits the status of the surgicalinstrument to be monitored by the clinician, for example. The controlcircuit can also try to fix the signal distortion and/or voltage drop byincreasing the signal gain, for example. When there is fluid intrusioninto an electrical interface, however, increasing the signal gain maynot resolve these issues.

In various instances, further to the above, the surgical instrument cancomprise a fan positioned to blow air across the electrical interfacewhen the signal distortion and/or voltage drop within one or moreelectrical circuits is high, or above a predetermined threshold. Invarious instances, the fan forms a part of the control circuit. In atleast one instance, the fan is positioned proximally with respect to theelectrical interface such that air is blown in a proximal-to-distaldirection, for example. In certain instances, the surgical instrumentcan be configured to at least partially insufflate the patient withcarbon dioxide, for example. In such instances, the insufflation pathcan pass over the electrical interface which can dry the electricalinterface and/or prevent fluid intrusion in the first place. The controlcircuit comprises a speed control circuit, such as a pulse widthmodulation (PWM) circuit, a frequency modulation (FM) circuit, and/or avariable-resistance circuit, for example, configured to operate the fanat different speeds. In such instances, the control circuit isconfigured to operate the fan at a higher speed when the signaldistortion and/or voltage drop is higher and at a lower speed when thesignal distortion and/or voltage drop is lower. In various instances,the patient can also be insufflated through one or more trocars, orports, extending into the patient. In such instances, the controlcircuit is configured to communicate with a surgical hub system when thefan is turned on, turned off, accelerated, and/or decelerated such thatthe insufflation amounts can be properly managed by the surgical hubsystem. When too much insufflation gas is being pushed into the patientby an insufflation system and/or a surgical instrument, and/or when theamount of insufflation gas being pushed into the patient through thesurgical instrument is increased too much, the surgical hub system canoperate to reduce the amount of insufflation gas being pushed into thepatient through the insufflation trocar. When the amount of insufflationgas being pushed into the patient through the surgical instrument isdecreased too much, the surgical hub system can operate to increase theamount of insufflation gas being pushed into the patient through theinsufflation trocar.

In addition to or in lieu of the above, the surgical instrumentcomprises a heating circuit positioned and configured to dry theelectrical interface when water intrusion in one of the electricalcircuits is detected by the control circuit. In at least one suchinstance, the heating circuit comprises a resistive heating circuit, forexample, comprising a heating resistor adjacent the electricalinterface. When the signal distortion and/or voltage drop exceeds apredetermined threshold, the control circuit can power the heatingcircuit and/or increase the current through the heating circuit, forexample. When the signal distortion and/or voltage drop falls below thepredetermined threshold, the control circuit can turn off the heatingcircuit immediately, power the heating circuit for a pre-set additionalperiod of time, and/or reduce the current in the heating circuit, forexample.

As discussed above, a shaft assembly can be selectively attachable to ahandle of a surgical instrument. As also discussed above, the shaftassembly can comprise a shaft flex circuit and the handle can comprise ahandle flex circuit. In various instances, the shaft flex circuit andthe handle flex circuit comprise electrical connectors whichinterconnect, or become electrically coupled, when the shaft assembly ismounted to the handle such that the flex circuits are placed inelectrical communication with one another. One or both of the electricalconnectors can comprise a seal which can seal the electricalinterconnection once the electrical connectors are mated; however, oneor both of the electrical connectors can comprise unsealed or exposedelectrical contacts prior to the interconnection being made. In certaininstances, the electrical contacts can be exposed to fluids and/orcontaminants. An alternative approach is illustrated in FIG. 101A whichdepicts a handle flex circuit 219220 and a shaft flex circuit 219520.The handle flex circuit 219220 comprises a flexible substrate andelectrical traces 219230 embedded in the flexible substrate. Similarly,the shaft flex circuit 219520 comprises a flexible substrate andelectrical traces 219530 embedded in the flexible substrate. Referringto FIG. 101B, the electrical traces 219230 and 219530 are positionedadjacent one another when the shaft assembly is mounted to the handleand are placed in communication with one another. In such instances, thetraces 219230 and 219530 form a capacitive and/or inductive connectioninterface and can communicate electrical signals and/or electrical poweracross the interface therebetween. As a result, the overlapping traces219230 and 219250 are enclosed and/or sealed such that their exposure tofluids and/or contaminants is reduced if not eliminated. The walls ofthe substrate surrounding the traces 219230 and 219530 can be thin and,in various instances, the traces 219230 and 219530 can be printed ontotheir respective substrates to improve the fidelity of theinterconnection therebetween.

As illustrated in FIGS. 101A and 101B, the traces 219230 and 219530comprise tips which overlap with one another when the flex circuits219220 and 219520 are interconnected. To facilitate thisinterconnection, the handle flex circuit 219220 comprises magnets 219240and the shaft flex circuit 219520 comprises magnets 219540 whicharranged in a manner so as to attract one another when brought intoclose approximation with one another and bring the flex circuits 219220and 219520 into contact with one another as illustrated in FIG. 101B.The magnets 219240 and 219540 are arranged in two pairs, but cancomprise any suitable number and/or arrangement.

A control circuit of a surgical instrument can be utilized to realizevariable rate control for a motor-driven system of the surgicalinstrument. Such motor-driven systems can include, for example, aclosing system, a firing system and/or an articulation system of asurgical instrument. In some instances, it is beneficial to utilize ahardware-only implementation of the control circuit to realize thevariable rate control of the motor-driven system. For example, ahardware-only implementation can be utilized to provide faster operationthan implementations which require software and/or firmware to beexecuted by a processing device. Also, a hardware-only implementationcan be utilized to eliminate the cost and complexity required withprocessors, software and/or firmware. Additionally, a hardware-onlyimplementation can offer increased reliability, increased durability andan increased life span of the control circuit. Furthermore, ahardware-only implementation can also expand options available forsterilization of the surgical instrument.

In various instances, the rotation of a knob of a surgical instrumentand/or the pulling or pressing of an input device of the surgicalinstrument can cause a proportional position change of the motor. Incertain instances, a variable pull of a switch or other input device ofthe surgical instrument can cause a proportional speed of motor advance.

FIG. 102 illustrates a control circuit 220000 of a surgical instrument.The control circuit 220000 is shown as a combinational logic circuit andis utilized to provide input signals and/or waveforms to a motorcontroller 220002 which controls the speed of rotation of a motor of thesurgical instrument. Responsive to the input signals from the controlcircuit 220000, the motor controller 200002 operates to alter rates ofaction of a device function based on a parameter that is sensed ortripped as a result of the function that is being performed. Forexample, in various instances, the device function may be thearticulation of an end effector of the surgical instrument, the rate ofaction may be the speed or velocity of the articulation away from alongitudinal axis of the shaft, and the parameter may be the position ofthe end effector relative to the longitudinal axis of the shaft. Invarious instances, the parameter that can be sensed or tripped is thestate of an input device, such as a switching device (either open orclosed), which can be changed or “bumped” by a user of the surgicalinstrument.

Further to the above, the control circuit 220000 includes a first ANDgate 220004, a monostable multivibrator 220006, an asynchronous counter220008, a first inverter 220010 (shown as a circle), a second AND gate220012, an OR gate 220014, a second inverter 220016 (shown as a circle)and a third AND gate 220018. In various instances, the control circuit220000 also includes the motor controller 22002.

A sensing device 220020, which is shown in FIG. 102 as a user switch, isconnected to a first input terminal 220022 of the first AND gate 220004and to an input terminal 220024 of the monostable multivibrator 220006.In various instances, the control circuit 220000 also includes thesensing device 220020, which may be implemented as a switching device,such as a limit switch, a position sensor, a pressure sensor, and/or aforce sensor, among others. According to various aspects, the sensingdevice 220020 may be implemented as an input device, such as a switchingdevice, which can be actuated or “bumped” by a user of the surgicalinstrument.

The sensing device 220020 is configured to sense a parameter associatedwith the surgical instrument and output a signal representative of thesensed parameter. For example, according to various aspects, the sensedparameter can be a user of the surgical instrument “pressing” or“bumping” the sensing device 220020. According to other aspects, thesensed parameter can be the end effector passing through a zone definedaround a centered state (e.g., through a zone defined relative to thelongitudinal axis of the shaft). The signal output by the sensing device220020 may be conditioned as needed (not shown) for input to the controlcircuit 220000. According to various aspects, the sensing device 220020may output a signal which is representative of a logic “1” or a “high”signal (e.g., 0.5 volts) when the end effector is not in the zonedefined around the centered state, and may output a signal which isrepresentative of a logic “0” or a “low” signal (e.g., 0.0 volts) whenthe end effector is in the zone defined around the centered state. It isto be understood that the above examples of 0.5 volts for a logic “1” ora “high” signal and 0.0 volts for a logic “0” or a “low” signal aremerely exemplary. Depending on the specific make and model of the logiccomponents utilized in the control circuit 220000, a voltage other than0.5 volts may be representative of a logic “1” or a “high” signal and avoltage other than 0.0 volts may be representative of a logic “0” or a“low” signal. As described in more detail hereinbelow, according tovarious aspects, a plurality of sensing devices 220020 (i.e., twosensing devices, three sensing devices, etc.) may output signals whichare for input to the control circuit 220000.

The monostable multivibrator 220006, also known as a “one-shot”,includes a resistor 220026 and a capacitor 220028 as depicted in FIG.102, a first output terminal 220030, and a second output terminal220032. The signal Q which is output from the second output terminal220032 is a compliment of the signal Q which is output from the firstoutput terminal 220030. The resistor 220026 and the capacitor 220028collectively form a RC circuit. The monostable multivibrator 220006 isstructured to have only one stable state (e.g., a logic “0” outputstate). When a suitable trigger signal or pulse from the sensing device220020 is applied to the input terminal 220024 of the monostablevibrator 220006 (e.g., when a user of the surgical instrument presses orbumps the sensing device 220020), the monostable vibrator 220006generates an output signal Q (e.g., a single output pulse of a specifiedwidth) at the first output terminal 220030 for a period of time, and inthe process is forced from its stable state (e.g., a logic “0” outputstate) to another state (e.g., a logic “1” output state). The outputsignal Q is either a “high” signal or a “low” signal, and the period oftime is determined by a time constant of the RC circuit. If noadditional “bump” has been applied by the user to the sensing device220020 and/or no trigger signal or pulse from the sensing device 220020has been applied to the input terminal 220024 of the monostablemultivibrator 220006 during the period of time, the monostablemultivibrator 220006 will return to its stable state after the period oftime has elapsed (e.g., the output signal Q will go from a logic “1”output state to a logic “0” output state). The first output terminal Q220030 is connected to a first input terminal 220034 of the second ANDgate 220012. The second output terminal 220032 is connected to a resetinput terminal 220036 of the asynchronous counter 220008.

As described in more detail hereinbelow, according to various aspects,the monostable multivibrator 220006 can be a retriggerable monostablemultivibrator. If the user applies another “bump” to the sensing device220020 and/or another valid trigger signal or pulse from the sensingdevice 220020 is applied to the input terminal 220024 of the monostablevibrator 220006 before the output signal Q has returned to the stablestate (e.g., a logic “0” state), the width of the pulse of the outputsignal Q will be increased. Stated differently, the output signal Q willremain in its unstable state (e.g., a logic “1” state) for a longerperiod of time. Any number of user-initiated “bumps” of the sensingdevice 220020 and/or any number of valid trigger signals or pulses froma plurality of sensing devices 220020 can be applied to the inputterminal 220024 of the monostable vibrator 220006 before the outputsignal Q has returned to the stable state, with each applicationoperating to further increase the width of the pulse of the outputsignal Q.

The asynchronous counter 220008 includes a plurality of flip-flops (notshown), where the first one of the flip-flops is clocked by an externalclock and each of the subsequent flip-flops are clocked by the output ofthe preceding flip-flop. Since the external clock signal accumulatespropagation delays as it ripples through the plurality of flip-flops,the asynchronous counter 220008 is also known as a ripple counter. Asshown in FIG. 102, the asynchronous counter 220008 includes a firstinput terminal 220038 which is connected to an output terminal 220040 ofthe first AND gate 220004, a reset input terminal 220036 which isconnected to the second output terminal 220032 of the monostablemultivibrator 220006, a first output terminal 220042, a second outputterminal 220044, and a third output terminal 220046. The first outputterminal 220042 of the asynchronous counter 220008 is connected to asecond input terminal 220048 of the second AND gate 220012. The secondoutput terminal 220044 of the asynchronous counter 220006 is connectedto a first input terminal 220050 of the OR gate 220014. The third outputterminal 220046 of the asynchronous counter 220006 is connected to aninput terminal 220052 of the first inverter 220010 (shown as a circle)which has an output terminal 220054 which is connected to a second inputterminal 220056 of the first AND gate 220004. According to variousaspects, the first inverter 220010 is incorporated into the first ANDgate 220004. The third output terminal 220046 of the asynchronouscounter 220008 is also connected to a second input terminal 220058 ofthe OR gate 220014.

The output terminal 220060 of the second AND gate 220012 is connected toa first input terminal 220062 of the third AND gate 220018. The outputterminal 220064 of the OR gate 220014 is connected to an input terminal220066 of the second inverter 220016 (shown as a circle) which has anoutput terminal 220068 which is connected to a second input terminal220070 of the third AND gate 220018. According to various aspects, thesecond inverter 220016 is incorporated into the third AND gate 220018.The output terminal 220064 of the OR gate 220014 is also connected to a“fast” input terminal 220072 of the motor controller 220002. The outputterminal 220074 of the third AND gate 220018 is connected to a “slow”input terminal 220076 of the motor controller 220002. According tovarious aspects, when the “slow” input terminal 220074 of the motorcontroller 220002 receives a “high” signal, the motor controller 220002operates to run a motor (e.g., an articulation motor) of the surgicalinstrument at a low speed. Similarly, when the “fast” input terminal220072 of the motor controller 220002 receives a high signal, the motorcontroller 200002 operates to run a motor (e.g., an articulation motor)of the surgical instrument at a high speed.

Although the control circuit 220000 is shown as a specific configurationof a hardware-only control circuit in FIG. 102, it will be appreciatedthat according to other aspects the functionality of the control circuit220000 (e.g., realizing proportional speed control for a motor-drivensystem of the surgical instrument) can be implemented with other logicelements and/or other arrangements of logic elements.

FIG. 103 illustrates timing diagrams 220100 associated with the controlcircuit 220000 of FIG. 102, in accordance with at least one aspect ofthe present disclosure. The first timing diagram 220102 is shown at thefar left side of FIG. 103, and is representative of an instance when auser of the surgical instrument “bumps” the sensing device 220020 asingle time, or when a single trigger signal or pulse from the sensingdevice 220020 is applied to the input terminal 220024 of the monostablevibrator 220006.

When the monostable multivibrator 220006 is in a stable state (e.g.,when the user has not yet “bumped” the sensing device 220020 or thesensing device 200020 is in an open condition) as shown on the left-mostside of FIG. 103, the output signal Q at the first output terminal220030 of the monostable multivibrator 220006 is a low signal, theoutput signals Q₀, Q₁ and Q₂ at the first, second and third outputterminals 220042, 220044, 220046 of the asynchronous counter 220008 arelow signals, and the signals at the “slow” and “fast” input terminals220076, 220072 to the motor controller 220002 are low signals.

When the user “bumps” the sensing device 220020 a single time or thesensing device 220020 is triggered a single time and/or transitions, asignal associated with the sensing device 220020 changes, and thechanged signal (e.g., in the form of a pulse going from high to low andthen back to high as shown in FIG. 103) is input at the input terminal220024 to the monostable multivibrator 220006. Responsive to the leadingedge of the pulse of the input signal, the Q output signal at the firstoutput terminal 220030 of the monostable multivibrator 220006transitions from a low signal to a high signal in the form of a pulsehaving a duration of T. The asynchronous counter 220008 recognizes thisfirst change (e.g., a change in count from 0 to 1) and operates totransition the output signal Q₀ at the first output terminal 220042 ofthe asynchronous counter 220008 from a low signal to a high signal inthe form of a pulse having a duration of T. The Q₁ and Q₂ signals at thesecond and third output terminals 220044, 220046 of the asynchronouscounter 220008 are not affected by the first change in the signalassociated with the sensing device 220020 and remain as low signals.

By having high signals at the first and second input terminals 220034,220048 of the second AND gate 220012, a high signal is at the outputterminal 220060 of the second AND gate 220012, and this high signal isalso at the first input terminal 220062 of the third AND gate 220018. Byhaving low signals at the first and second input terminals 220050,220058 of the OR gate 220014, the signals at the output terminal 220064of the OR gate 220064 and at the “fast” terminal of the motor controller220002 are also low signals. The low signal from the output terminal220064 of the OR gate is converted from a low signal to a high signal bythe second inverter 220016, and this high signal is at second inputterminal 220070 of the third AND gate 220018. By having high signals atthe first and second input terminals 220062, 220070 of the third ANDgate 220018, the signal at the output terminal 220074 of the third ANDgate is a high signal, and this high signal (in the form of a pulsehaving a duration of T) is also at the “slow” input terminal 220076 ofthe motor controller 220002. Thus, when a user “bumps” the sensingdevice 220020 a single time or a single trigger signal or pulse from thesensing device 220020 is applied to the input terminal 220024 of themonostable vibrator 220006, the motor controller 220002 causes the motorof the surgical instrument to run at a “slow” speed for a time T.

The second timing diagram 220104 is shown to the immediate right of thefirst timing diagram 220102, and is representative of an instance when auser “bumps” the sensing device twice or two trigger signals or pulsesfrom the sensing device 220020 (or from sensing devices 220020) areapplied to the input terminal 220024 of the monostable vibrator 220006,where the second of the “bumps” or of the trigger signals or pulses isapplied to the input terminal 220024 of the monostable vibrator 220006before the output signal Q has returned to the stable state (e.g., alogic “0” state). The second timing diagram 22104 is the same as thefirst timing diagram 220102 up until the time that the second “bump” orthe second trigger signal or pulse occurs. As the second of the “bumps”or of the trigger signal or pulse occurs before the output signal Q hasreturned to the stable state (e.g., a logic “0” state), the width of thepulse of the output signal Q is increased (the output signal Q remains ahigh signal for a period of time), and the width of the pulse of thesignal input to the “slow” input terminal 220076 of the motor controller220002 is increased (the signal remains a high signal for a period oftime), which results in the motor running at the “slow” speed from thetime of the first “bump” or of the trigger signal or pulse until theoccurrence of the falling edge of the output signal Q.

Additionally, the asynchronous counter 220008 recognizes this secondchange (e.g., a change in count from 1 to 2) and operates to transitionthe output signal Q₀ at the first output terminal 220042 of theasynchronous counter 220008 from a high signal back to a low signal, andto transition the output signal Q₁ at the second output terminal 220044of the asynchronous counter 220008 from a low signal to a high signal inthe form of a pulse having a duration of T. The Q₂ signal at the thirdoutput terminal 220046 of the asynchronous counter 220008 is notaffected by the second change in the signal associated with the sensingdevice 220020 and remains a low signal. Thus, when two user-initiated“bumps” of the sensing device 220002 or two trigger signals or pulsesfrom the sensing device 220020 (or from a plurality of sensing devices220020) are applied to the input terminal 220024 of the monostablevibrator 220006, where the second of the two “bumps” or of the triggersignals or pulses is applied while the output signal Q is still high,the motor controller 220002 operates to cause the motor of the surgicalinstrument to run at a “slow” speed for a time greater than T. In thisinstance, the time greater than T is the sum of the time T shortened bythe leading edge of the second “bump” or of the second trigger signal orpulse plus the time T.

The third timing diagram 220106 is shown to the immediate right of thesecond timing diagram 220104, and is representative of an instance whenthree “bumps” are applied to the sensing device 220020 or three triggersignals or pulses from the sensing device 220020 (or from sensingdevices 220020) are applied to the input terminal 220024 of themonostable vibrator 220006, where the second and third of the “bumps” orof the trigger signals or pulses are applied to the input terminal220024 of the monostable vibrator 220006 before the output signal Q hasreturned to the stable state (e.g., a logic “0” state). The third timingdiagram 22106 is the same as the second timing diagram 220104 up untilthe time that the third “bump” or trigger signal or pulse occurs. As thethird “bump” or trigger signal or pulse occurs before the output signalQ has returned to the stable state (e.g., a logic “0” state), the widthof the pulse of the output signal Q is increased (the output signal Qremains a high signal for a period of time). This causes the motorcontroller 220002 to run the motor at a “slow” speed during the timeassociated with the first and second “bumps” or trigger signals orpulses until the occurrence of the rising edge of the output signal Q₀,the falling edge of the output signal Q₁ and the rising edge of theoutput signal Q₂. Thereafter, the motor controller 220002 operates torun the motor at a “fast” speed for the time T after the third “bump” ortrigger signal or pulse until the occurrence of the falling edge of theoutput signal Q, the falling edge of the signal Q₀ and the falling edgeof the output signal Q₂.

The asynchronous counter 220008 recognizes this third change (e.g., achange in count from 2 to 3) and operates to transition the outputsignal Q₁ at the second output terminal 220044 of the asynchronouscounter 220008 from a high signal back to a low signal, to transitionthe output signal Q₀ at the first output terminal 220042 of theasynchronous counter 220008 from a low signal to a high signal in theform of a pulse having a duration of T, and to transition the outputsignal Q₂ at the third output terminal 220046 of the asynchronouscounter 220008 from a low signal to a high signal in the form of apulse. As shown in FIG. 103, due to some propagation delay, the outputsignal Q₂ transitions somewhat later than the output signal Q₀ does, andthus has a duration somewhat less than T. The transitions of the Q₀output signal, the Q₁ output signal and the Q₂ output signal operate tocause the signal at the slow input terminal 220076 of the motorcontroller 220002 to transition from a high signal back to a low signal,and to cause the signal at the “fast” input terminal 220072 of the motorcontroller 220002 to transition from a low signal to a high signal(e.g., in the form of a pulse having a duration of T). Thus, when three“bumps” or trigger signals or pulses from the sensing device 220020 (orfrom a plurality of sensing devices 220020) are applied to the inputterminal 220024 of the monostable vibrator 220006, where the second andthird of the three “bumps” or trigger signals or pulses are appliedwhile the Q output signal is still high, the motor controller 220002operates to cause the motor of the surgical instrument to run at a“slow” speed for a time greater than T (i.e., the sum of the time Tshortened by the leading edge of the second trigger signal or pulse plusthe time T), then to run at a “fast” speed for the time T.

The fourth timing diagram 220108 is shown to the immediate right of thethird timing diagram 220106, and is representative of an instance whenmultiple (e.g., more than three) “bumps” are applied to the sensingdevice 220020 or multiple trigger signals or pulses from the sensingdevice 220020 (or from sensing devices 200020) are applied to the inputterminal 220024 of the monostable vibrator 220006, where each of the“bumps” or trigger signals or pulses occur after the first “bump” isapplied to the sensing device 220020 or after the first trigger signalor pulse is applied to the input terminal 220024 of the monostablevibrator 220006 before the output signal Q has returned to the stablestate (e.g., a logic “0” state). The fourth timing diagram 22108 is thesame as the third timing diagram 220106 up until the time that thefourth “bump” or trigger signal or pulse occurs. As the fourth “bump” ortrigger signal or pulse occurs before the output signal Q has returnedto the stable state (e.g., a logic “0” state), the width of the pulse ofthe output signal Q is increased (the output signal Q remains a highsignal for a period of time). This causes the motor controller 220002 tocause the motor to continue to run at a “fast” speed as long as the Qoutput signal is high (e.g. for the time T after the fourth “bump”,trigger signal or pulse). The asynchronous counter 220008 is reset onthe falling edge of the output signal Q2.

The asynchronous counter 220008 recognizes this fourth change (e.g., achange in count from 3 to 4) and operates to extend the width of thepulse of the output signal Q₁ at the second output terminal 220044 ofthe asynchronous counter 220008, and to shorten the duration of thesecond pulse of the output signal Q₀ at the first output terminal 220042of the asynchronous counter 220006.

As shown in the timing diagram 220108, as additional “bumps” (e.g., afifth “bump”, a sixth “bump”, etc.) are applied to the sensing device220020 or additional trigger signals or pulses (e.g., a fifth triggersignal or pulse, a sixth trigger signal or pulse, etc.) from the sensingdevice 220020 (or from sensing devices 200020) are applied to the inputterminal 220024 of the monostable vibrator 220006 before the outputsignal Q has returned to the stable state (e.g., a logic “0” state), thewidth of the pulse of the output signal Q₂ is extended until a time Thas elapsed after the last “bump”, trigger signal or pulse has beenapplied before the output signal Q has returned to the stable state(e.g., a logic “0” state). Thus, when four or more “bumps” or triggersignals or pulses have occurred, where the second, third, fourth, etc.of the four or more “bumps” or trigger signals or pulses are appliedwhile the Q output signal is still high, the motor controller 220002operates to cause the motor of the surgical instrument to run at a“slow” speed for a time greater than T (i.e., the sum of the time Tshortened by the leading edge of the second trigger signal or pulse plusthe time T), then to run at a “fast” speed until a time T has elapsedafter the last “bump”, trigger signal or pulse is applied before theoutput signal Q has returned to the stable state. The Q₂ output signalremains high until the asynchronous counter 220008 is reset on thefalling edge of the output signal Q.

In some applications, the control circuit 220000 does not have to be assophisticated as is shown in FIG. 102. For example, in someapplications, it may be desirable to run the motor at a “slow” speedinitially for a short period of time then allow the motor to speed up toa faster speed or to a full speed. This can be useful, for example, whenarticulating an end effector of a surgical instrument. For example,according to various aspects, a control circuit for the articulationsystem of the surgical instrument can be implemented with an“end-of-stoke” switch that allows the articulation motor to be operatedin the reverse direction but not any further in the forward directionwhile the “end-of-stroke” switch is tripped. In other applications, itmay be desirable to change the speed of the motor from a slow speed to afast speed, or from a fast speed to a slow speed, for a controllableperiod of time.

FIG. 104 illustrates a control circuit 220200 of a surgical instrument.The control circuit 220200 is shown as a combinational logic circuit andmay be utilized to provide input signals and/or waveforms to a motorcontroller (not shown for purposes of simplicity in FIG. 104).Responsive to the input signals from the control circuit 220200, themotor controller operates to change the motor speed when an input deviceof the surgical instrument is held in a given position for a period oftime.

The control circuit 220200 is similar to the control circuit 220000 ofFIG. 102 in that the control circuit 220200 includes a monostablemultivibrator 220202, a first inverter 220204, and a second inverter220206, but is different in that it does not include the othercomponents of control circuit 220000 and has a different functionality.According to various aspects, the control circuit 220200 includes themotor controller, which may be similar or identical to the motorcontroller 220002 of FIG. 102.

A sensing device 220208, which is shown in FIG. 104 as a switchingdevice, is connected to an input terminal 220210 of the first inverter220204, to an input terminal 220212 of the second inverter 220206, andto a first input terminal 220214 of the monostable multivibrator 220202.According to various aspects, the control circuit 220200 also includesthe sensing device 220208, which may be implemented as a trigger, aswitching device, such as a push button, a limit switch, a positionsensor, a pressure sensor, and/or a force sensor, among others.

The monostable multivibrator 220202 can be similar or identical to themonostable vibrator 220006, and includes a resistor 220216 and acapacitor 220218 as depicted in FIG. 104, the first input terminal220214, a reset input terminal 220220, and a first output terminal220222. The resistor 220216 and the capacitor 220218 collectively form aRC circuit. The first output terminal 220222 of the monostablemultivibrator 220202 is connected to a “motor fast” input terminal ofthe motor controller.

The first inverter 220204 also includes an output terminal 220224 whichis connected to a “motor slow” input terminal of the motor controller.The second inverter 220206 also includes an output terminal 220226 whichis connected to the reset input terminal 220220 of the monostablemultivibrator 220202.

In operation, when the sensing device 220208 is changed from an openposition as shown in FIG. 104 to a closed position and held in place fora period of time (e.g., by a user of the surgical instrument), a “low”signal is applied to the input terminal 220210 of the first inverter220204, to the input terminal 220212 of the second inverter 220206, andto the first input terminal 220214 of the monostable multivibrator220202. The first inverter 220204 operates to invert the “low” signal toa “high” signal at the output terminal 220224 of the first inverter220204, which results in a “high” signal being at the “motor slow” inputterminal of the motor controller, resulting in a motor (e.g., anarticulation motor) of the surgical instrument being operated at a“slow” speed. The second inverter 220206 also operates to invert the“low” signal to a “high” signal at the output terminal 220226 of thesecond inverter 220206, which results in a “high” signal being at thereset input terminal 220220 of the monostable multivibrator 220202. Oncethe sensing device 220208 is released from its “held” position, after aperiod of time determined by a time constant of the RC circuit, themonostable multivibrator 220202 operates to generate a “high” signal(the output signal Q) at the output terminal 220222 of the monostablemultivibrator 220202, which results in a “high” signal being at the“motor fast” input terminal of the motor controller. The time constantcan be on the order of approximately 0.5 seconds to 1.0 seconds, forexample. The “high” signal at the “motor fast” input terminal of themotor controller results in the motor of the surgical instrumentchanging from a “slow” speed of rotation to a “fast” of “full” speed ofrotation. The timer of the monostable multivibrator 220202 is reset oncethe sensing device 220208 changes from a closed state back to an openstate (e.g., by releasing the push button). Thus, in cooperation withthe sensing device 220208, the control circuit 220200 can be utilized tocreate a “slow” motor speed for a controllable period of time, followedby the speed of the motor then being increased to a “fast” motor speedor all the way up to a “full” motor speed.

Although the control circuit 220200 is described above in the context ofa controllable “slow” speed followed by a “fast” speed, it will beappreciated that the control circuit 220200 can also be configured torealize a controllable “fast” speed followed by a “slower” speed. Itwill be appreciated that the control circuit 220200 can be implementedwith solid state circuits configured to create different motor speeds.According to various aspects, the surgical instrument can include aswitching system configured to slow the articulation motor as it passesthru a predefined portion of the articulation arc. According to variousaspects, the surgical instrument can also include a switching systemconfigured to rotate an anvil to an open position at a relatively fastspeed. For example, a switch could be located on the anvil at pointwhere positive opening tabs contact, and the closing of the switch canoperate to cause a fast period of opening when the switch is tripped.According to various aspects, the control circuit can be configured toprevent a single point failure in motor control circuit.

As discussed above, a control circuit is configured to control the powerdelivered to an electric motor. In some instances, a light emittingdiode (LED) array can be configured as a proportional display to showmotor speed or current. For example, a display driver such as the LM3914by Texas Instruments can be utilized to drive a display that isproportional to current. Different colors, different placement ordifferent LEDs (or even skipping some LEDs on the display array) can beutilized to emphasize that the current is proportional to the load onthe motor system.

FIG. 104A illustrates a control circuit 220400 configured to indicatethe power being delivered to the electric motor. The control circuit220400 comprises a power supply 220410, a motor control circuit 220420,a LM3914 integrated circuit (or similar display driver) 220430, and asegmented display 220450 in communication with a plurality of gates orcontacts 220440 defined on the integrated circuit 220430. The integratedcircuit 220430 comprises ten comparators and a resistor scaling network,for example; however, the integrated circuit 220430 can comprise anysuitable arrangement to drive a graduated display (See FIG. 1046) whichindicates the current being drawn by the electric motor. The segmenteddisplay 220450 comprises ten light emitting diodes (LEDs), i.e.,220451-220460, which are each in communication with one of the contacts220440. For the control circuit 220400, the LEDs 220451-220460 light upin proportion to the motor current being drawn, which is in proportionto the torque applied/delivered by the motor, either in the forwarddirection or the reverse direction.

Each LED represents 10 percent of the maximum applicable current to theelectric motor. Thus, the LED 220541 is illuminated when the electricmotor is drawing more than 10 percent of the total current available(and when the motor is applying/delivering a low torque). If the motorcurrent draw does not exceed 20 percent, however, the second LED 220452is not illuminated—nor are the LEDs 220453-220460. When the electricmotor is drawing more than 20 percent of the total current available,the second LED 220452 is illuminated, and so forth. When the electricmotor is drawing 100% of the available current, all of the LEDs220451-220460 are illuminated (and when the motor is applying/deliveringa high torque).

In at least one alternative aspect, some of the LEDs, such as the ninthand tenth LEDs 220459 and 220460 represent an overdrive condition of theelectric motor. Moreover, while ten LEDs provide a convenientlyunderstandable display, any suitable number of LEDs could be used, suchas three LEDs, for example. In such instances, a first LED, whenilluminated, would represent a low torque condition, a second LED, whenilluminated, would represent a mid-torque condition, and a third LED,when illuminated, would represent a high-torque condition, for example.Although FIGS. 104A and 1046 are described in the context of currentbeing drawn by the motor, it will be appreciated that similar circuitrycould be utilized to provide an indication of motor speed by measuringand displaying motor voltage instead of motor current.

FIG. 104C illustrates a surgical instrument comprising a handle 220100.The handle 220100 comprises a handle housing 220110, actuators, and acontrol system configured to operate the surgical instrument. Similar toother surgical instruments disclosed herein, the control system of thehandle 220100 is configured to communicate with a surgical hub system.While the handle 220100 can be configured to communicate wirelessly withthe surgical hub system via electromagnetic waves, the handle 220100comprises an acoustic speaker and/or an acoustic sensor configured tocommunicate with the surgical hub system. The surgical hub system alsocomprises an acoustic speaker and/or an acoustic sensor in the sameroom, or at least within sufficient auditory range, as the surgicalinstrument so as to communicate with the surgical instrument. Such datacommunication is wireless, and can comprise various chirps, for example,which may or may not be within the auditory range of a human being. Thesignals can be above, within, and/or below the auditory range of a humanbeing. An acoustic system advantageously does not rely on emittingelectromagnetic waves which may interfere with the operation of asurgical instrument and/or system, for example, in the same operatingroom.

In some instances, it is desirable to configure a circuit to determinethe suitability of the circuit before the circuit is energized. Forexample, it would be desirable to detect the return path capacity of anelectrosurgical circuit, and if the return path capacity is notsufficient, limit the amount of electrosurgical energy to be applied toa patient without exceeding a predefined localized current threshold.According to various aspects, the surface area and the resistance levelsof the grounding pad are used to determine the return path capacity, andif the return path capacity is found to be insufficient, the output ofthe monopolar generator is limited to a level below the localizedcurrent level threshold. In practice, it is beneficial to maximize thegenerator coupling to patient for the highest efficiency and to realizethe best electrosurgical performance while limiting the power when thepatient contact quality is changed or goes below a threshold where aburn is possible. According to various aspects, a printed flex circuitof the electrosurgical system includes a predefined zone with an alteredarea which acts as a fuse to define the maximum capacity of the returnpath.

FIG. 105 illustrates a surgical system 220300, in accordance with atleast one aspect of the present disclosure. The surgical system 220300includes a surgical hub 220302, an electro-surgical instrument 220304, acapacitive return pad 220306, and a cable or cord 220308 which connectsthe capacitive return pad 220306 with the surgical hub 220302. Thecapacitive return pad 220306 and the cable or cord 220308 collectivelyform a return path for the electrosurgical energy applied to the patientvia the electrosurgical instrument 220304. When applying electrosurgicalenergy to a patient, it is important to ensure that the current-carryingcapacity of the return path is sufficient to handle the amount ofelectrosurgical energy applied to the patient.

The surgical hub 220302 includes a monopolar generator module 220310,and the monopolar generator module 220310 includes a sensing device (seeFIG. 106) configured to sense electrical continuity in the return pathfor the electrosurgical energy. Various aspects of a surgical hub aredescribed in more detail in U.S. patent application Ser. No. 15/940,629,entitled COMPUTER IMPLEMENTED INTERACTIVE SURGICAL SYSTEMS, filed onMar. 29, 2018, the disclosure of which is hereby incorporated byreference in its entirety. Various aspects of a electro-surgicalinstrument and a capacitive return pad are described in more detail inU.S. patent application Ser. No. 16/024,090, entitled CAPACITIVE COUPLEDRETURN PAD WITH SEPARABLE ARRAY ELEMENTS, filed on Jun. 29, 2018, thedisclosure of which is hereby incorporated by reference in its entirety.

As described in more detail hereinbelow, the surgical system 220300 isconfigured to detect the current-carrying capacity of the return path(by sensing the continuity of the return path) and limit the maximumamount of electrosurgical energy applied to the patient (by controllingthe electrosurgical energy delivered by the monopolar generator module220310), without exceeding a predefined localized current threshold.

FIG. 106 illustrates a schematic diagram 220400 which is representativeof current and signal paths of the surgical system 220300 of FIG. 105,in accordance with at least one aspect of the present disclosure.Electrosurgical current is supplied by the monopolar generator module220310 of the surgical hub 220302 to the electro-surgical instrument220304, where is it selectively applied to a patient 220312. The appliedelectrosurgical current passes through the body of the patient 220312and is received by the capacitive return pad 220306, then subsequentlypasses through the cable or cord 220308 back to the monopolar generatormodule 220310 of the surgical hub 220302 to complete the path followedby the electrosurgical current.

Although the sensing device 220314 of the monopolar generator module220310 of the surgical hub 220302 is shown schematically in FIG. 106 assensing the electrical continuity between the capacitive return pad220306 and the electrosurgical instrument 220304, it will be appreciatedthat the sensing device 220314 senses the electrical continuity from thecapacitive return pad 220306 and the cable or cord 220308 to theelectrosurgical instrument 220304 via the sensing device 220314positioned within the monopolar generator module 220310. The sensingdevice 220314 operates to monitor the continuity, and is configured togenerate an output signal which is representative of the integrityand/or current carrying-capacity of the return path. The output signalgenerated by the sensing device 220314 is passed to a control system220316 of the monopolar generator module 220310, and the control system220316 operates to control the amount of electrosurgical energydelivered to the electrosurgical instrument 220304. In instances wherethe continuity of the return path is less than absolute (e.g., where theintegrity of the return path varies from absolute), the control system220316 operates to limit the amount of electrosurgical energy deliveredto the electrosurgical instrument 220304, without exceeding a predefinedlocalized current threshold.

FIG. 107 illustrates a graph 220500 which shows a relationship between acontinuity level of the patient 220312 and the level of electrosurgicalpower supplied by the monopolar generator module 220310 of the surgicalsystem 220300 of FIG. 105, in accordance with at least one aspect of thepresent disclosure. The continuity level of the patient 220312, asmeasured by the resistance of the patient 220312, can serve as a proxyfor the continuity level of the return path of the surgical system220300. The graph 220500 includes two horizontal axes—an “upper”horizontal axis 220502 and a “lower” horizontal axis 220504. The time tis shown along the “lower” horizontal axis 220504, but is not shownalong the “upper” x-axis 220502 for purposes of clarity. However, asindicated by the vertical dashed lines shown in FIG. 107, the “upper”horizontal axis 220502 and the “lower” horizontal axis 220504 arealigned with one another. The graph 220500 also includes two verticalaxes—an “upper” vertical axis 220506 and a “lower” vertical axis 220508.The level of electrosurgical power supplied by the monopolar generatormodule 220310 of the surgical system 220300 is shown along the “upper”y-axis 220506 and the continuity level of the patient 220312, asmeasured by the resistance of the patient 220312, is shown along the“lower” y-axis 220508.

The graph 220500 further includes a maximum power threshold 220510 forthe monopolar generator module 220310, a potential power level 220514available at the electrosurgical instrument 220304 for application tothe patient 220312, a user setting 220516 for the power level suppliedby the monopolar generator module 220310, the actual power level 220518of electrosurgical energy applied by the electrosurgical instrument220304, and the electrical continuity 220520 of the patient 220312, asmeasured by the resistance of the patient 220312. As described in moredetail hereinbelow, as the continuity of the patient 220312 varies(which corresponds to variations of the detected return path integrity),the level of electrosurgical energy supplied by the monopolar generatormodule 220310 varies.

Starting at time t=0 at the left hand side of the “lower” horizontalaxis 220504, as well as at the left hand side of the “upper” horizontalaxis 220502, and moving toward time t₁, as the continuity of the patient220312 begins to increase, the level of power supplied by the monopolargenerator module 220310 begins to increase. From time t₁ to time t₂, asthe continuity of the patient 220312 levels off and remains relativelyconstant, the level of power supplied by the monopolar generator module220310 levels off and remains relatively constant. From time t₂ to timet₃, as the continuity of the patient 220312 further increases, the levelof power supplied by the monopolar generator module 220310 furtherincreases and reaches the user setting 220516 for the monopolargenerator module 220310. From time t₃ to time t₄, as the continuity ofthe patient 220312 levels off and remains relatively constant, the levelof power supplied by the monopolar generator module 220310 levels offand remains relatively constant. At time t₄, as the continuity level ofthe patient 220312 decreases, the level of power supplied by themonopolar generator module 220310 decreases. As shown in FIG. 107,according to various aspects, if a loss of integrity of the return pathis detected, the power supplied by the monopolar generator module 220310can be turned off (the level of power supplied by the monopolargenerator module 220310 decreases to zero) for a period of time to allowfor the integrity of the return path to be verified (e.g., by thecontrol system 220316 of the monopolar generator module 220310) beforeallowing for the power to start being supplied again by the monopolargenerator module 220310. In FIG. 107, the period of time is representedby the wait time t_(w) which is shown as the period of time between timet₄ and time t₅.

From time t₄ to time t₅, while the power supplied by the monopolargenerator module 220310 is shown as zero, the continuity of the patient220312 levels off and remains relatively constant. At time t₅, once thewait time t_(w) has been reached, the power to the monopolar generatormodule 220310 is restored and the power supplied by the monopolargenerator module 220310 increases. From time t₅ to time t₆, as thecontinuity of the patient 220312 continues to remain relativelyconstant, the level of power supplied by the monopolar generator module220310 levels off and remains relatively constant. At time t₆, as thecontinuity level of the patient increases again, the level of powersupplied by the monopolar generator module 220310 increases again, inthis case up to but not exceeding the power level associated with theuser setting 220516. After time t₆, as the continuity of the patient220312 levels off and then continues to remain relatively constant, thelevel of power supplied by the monopolar generator module 220310 levelsoff at the power level associated with the user setting 220516 and thenremains relatively constant.

According to various aspects, to more easily accomplish certainfunctions (e.g., articulation), the surgical instrument includes one ormore flexible circuits. According to various aspects, the flexiblecircuits are configured such that (1) the impact of any vibration on theflexible circuit is minimized, (2) solid chip attachment locations aresealed off from fluids and/or (3) the flexible circuits are easilyinner-connectable to one another. According to various aspects, thesubstrates of one or more of the flexible circuits are bio-compatiblewith tissue of the patient, and such flexible circuits can be implantedwithin the patient. According to various aspects, the flexible circuitscan have tubular part features for housing leads from the flexiblecircuit while the flexible circuit is being assembled but notnecessarily at the final assembly locations. According to variousaspects, electrical and/or mechanical sensors can be integrated into theflexible circuits.

Shielding can be integrated with/built into the flexible circuits toprevent unwanted radio-frequency (RF) interference from affecting theperformance of the flexible circuits. In certain aspects, the flexiblecircuits can include various configurations of twisted pair wiring. Inaddition to providing for the transmission of power and/or signalswithin the surgical instrument, the twisted pair wiring can beconfigured to provide one or more secondary functions. Such secondaryfunctions can include, for example, shielding the twisted pair wiringfrom electromagnetic interference, short-circuit detection, and/orcontamination detection.

FIG. 108 illustrates a flexible circuit 220600 of a surgical instrument.The flexible circuit 220600 includes a twisted pair of conductors, wherethe twisted pair of conductors includes a “top” conductive trace 220602and a “bottom” conductive trace 220604. As shown in FIG. 108, the “top”and “bottom” conductive traces 220602, 220604 overlap one another atregular intervals. When a current or a signal is being carried throughthe twisted pair of conductors, the overlapped configuration of the“top” and “bottom” conductive traces 220602, 220604 operates to betterprotect the current or signal from potential interference from anexternal electromagnetic field. This is particularly true when theprimary macro-direction of the flexible circuit 220600 is parallel tothe source of the electromagnetic field which can cause the potentialinterference.

The flexible circuit 220600 also includes a first layer 220606 of aninsulative material, a second layer 220608 of an insulative material anda third layer 220610 of an insulative material. The first layer 220606of the insulative material is positioned “below” the “bottom” conductivetrace 220604. The second layer 220608 is positioned “above” the “bottom”conductive trace 220604 and “below” the “top” conductive trace 220602(i.e., between the “top” and “bottom” conductive traces 220602, 220604).The third insulative layer 220610 is positioned “above” the “top”conductive trace 220602. According to various aspects, the “bottom”conductive trace 220604 is formed directly on the first layer 220606 ofthe insulative material, and the “top” conductive trace 220602 is formeddirectly on either the second layer 220608 of the insulative material orthe third layer 220610 of the insulative material. According to variousaspects, the first layer 220606, the second layer 220608 and the thirdlayer 220610 each comprise a polymer such as, for example, a polyimide.

FIG. 109 illustrates a cross-section of the flexible circuit 220600 ofFIG. 108. The hatched areas shown on the “top” and “bottom” conductivetraces 220602, 220604 represent the areas where the “top” and “bottom”conductive traces 220602, 220604 overlap one another. As shown in FIG.109, when a source 220612 generates an electromagnetic field 220614(shown as electromagnetic field lines), the overlapped configuration ofthe “top” and “bottom” conductive traces 220602, 220604 operate to blockor reject the electromagnetic field 220614 which can cause the potentialinterference, especially so along the direction of the dashed line220616. According to various aspects, flexible circuits other than thosewith twisted pairs of conductors can be configured to provide theabove-mentioned secondary functions.

FIG. 110 illustrates a flexible circuit 220700 of a surgical instrument.The flexible circuit 220700 includes a first plurality of conductivetraces 220702 and a second plurality of conductive traces 220704, wherethe first and second pluralities of conductive traces 220702, 220704 arepositioned at different layers of the flexible circuit 220700. Theflexible circuit 220700 also includes a first layer 220706 of aninsulative material, a second layer 220708 of an insulative material, athird layer 220710 of an insulative material, a fourth layer 22712 of aninsulative material, and a fifth layer 22714 of an insulative material.The first layer 220706 of the insulative material is positioned “below”the second plurality of conductive traces 220704. The second layer220708 is positioned “above” the second plurality of conductive traces220704 and “below” the first plurality of conductive traces 220702(i.e., between the first and second pluralities of conductive traces220702, 220704). The third insulative layer 220610 is positioned “above”the first plurality of conductive traces 220702. According to variousaspects, the second plurality of conductive traces 220704 is formeddirectly on the first layer 220706 of the insulative material, and thefirst plurality of conductive traces 220702 is formed directly on eitherthe second layer 220708 of the insulative material or the third layer220710 of the insulative material. According to various aspects, thefirst layer 220706, the second layer 220708, the third layer 220710, thefourth layer 220712 and the fifth layer 220714 each comprise a polymersuch as, for example, a polyimide.

Referring to FIG. 111, the flexible circuit 220700 further includes afirst shield layer 220716, a second shield layer 220718, and verticalshields 220720. The vertical shields 220720 are formed through vias inthe first, second and third layers 220706, 220708, 220710 of theinsulative material. The first shield layer 220716, the second shieldlayer 220718, and the vertical shields 220720 collectively operate tobetter protect currents or signals being carried through the firstand/or second pluralities of conductive traces 220702, 220704 frompotential interference from an external electromagnetic field. The firstshield layer 220716 is positioned “above” the third layer 220710 ofinsulative material and “below” the fifth layer 220714 of insulativematerial (i.e., between the third and fifth layers 220710, 220714 ofinsulative material). The second shield layer 220718 is positioned“above” the fourth layer 220712 of insulative material and “below” thefirst layer 220706 of insulative material (i.e., between the fifth andfirst layers 220712, 220706 of insulative material). The verticalshields 220720 are connected to the first and second shield layers220712, 220714, and surround the “left” and “right” sides of the firstand second pluralities of conductive traces 220702, 220704. As the firstshield layer 220712 covers the “bottom” of the second plurality ofconductive traces 220704 and the second shield layer 220714 covers the“top” of the first plurality of conductive traces 220702, the firstshield layer 220712, the second shield layer 220714 and the verticalshields 220720 collectively cooperate to form an electromagnetic shieldwhich surrounds a cross-section of the first and second pluralities ofconductive traces 220702, 220704.

Further to the above, the flexible circuit 220700 can additionallyinclude shield traces 220722 (see FIG. 111) which can be positionedalongside and along the length of the “left” and “right” sides of thefirst and second pluralities of conductive traces 220702, 220704 suchthat the first shield layer 220712, the second shield layer 220714, thevertical shields 220720 and the trace shields 220722 collectivelycooperate to form an electromagnetic shield which surrounds a length ofthe first and second pluralities of conductive traces 220702, 220704.The position and arrangement of the first, second, third, fourth and/orfifth layers 220706, 220708, 220710, 220712, 220714 of insulativematerial provide the secondary function of providing short-circuitprotection between the first and second pluralities of conductive traces220702, 220704 and/or between the electromagnetic shield and the firstand second pluralities of conductive traces 220702, 220704. Byeffectively surrounding a length of the first and second pluralities ofconductive traces 220702, 220704, the first shield layer 220712, thesecond shield layer 220714, the vertical shields 220720 and the traceshields 220722 collectively operate to protect the flexible circuit220700 from potential interference from an external electromagneticfield.

Further to the above, a flex circuit of a surgical instrument cancomprise components configured to absorb, distribute, and/or otherwiseaddress electromagnetic interference (EMI) from components within thesurgical instrument and/or an adjacent surgical instrument, for example.Referring to FIG. 111A, a circuitous flex circuit 219520 extendsalongside a shaft shroud 219510 and, in certain instances, passesclosely to an EMI emitting component, such as 219590, for example. Theflex circuit further comprises components 219550, such as ferrites,inductors, capacitors, and/or snubber networks, for example, where theyare needed. Smaller components can be used if the burden of absorbingthe EMI is shared across multiple components. In certain instances, thecomponents 219550 bridge or extend between two or more conductive traces219530 in the flex circuit 219520.

The aspects which provide for provide short-circuit detection and/orcontamination detection are described with reference to FIGS. 101A and101B hereinabove.

A control circuit of a surgical instrument can be utilized to controlone or more motor-driven systems of the surgical instrument. Suchmotor-driven systems can include an end effector closing system, an endeffector articulation system, and/or a firing system, for example. Insome instances, it is beneficial to utilize a parameter of amotor-driven system to control the motor-driven system. For example, asexplained in greater detail below, a parameter such as acoustic data,vibration data, and/or acceleration data associated with themotor-driven system can provide an indication that one or morecomponents of the motor-driven system is experiencing degradation,operating in a damaged state, and/or heading toward failure, forexample, and can be utilized to control the motor-driven system in lightof these potential issues.

FIG. 112 illustrates a control circuit 221000 of a surgical instrument.The control circuit 221000 is configured as a closed-loop system whichutilizes an acoustic measurement to control the rotation speed of anelectric motor, such as a drive motor, for example, of the surgicalinstrument. As the rotation speed of an electric motor has a distinctrelationship to the torque applied/delivered by the electric motor (thespeed and the torque can be inversely proportional to one another), thecontrol circuit 221000 can also be considered as being configured as aclosed-loop system which utilizes an acoustic measurement to control thetorque applied/delivered by an electric motor, such as a drive motor,for example, of the surgical instrument. For purposes of simplicity, thecontrol circuit 221000 will be described hereinafter in the context ofcontrolling the rotation speed of the electric motor of the surgicalinstrument.

The control circuit 221000 includes at least one acoustic sensor 221002,at least one signal conditioner 221004, at least one Fast FourierTransform (FFT) circuit 221006, at least one frequency-to-voltageconverter 221008, and at least one summing amplifier 221010. The controlcircuit 221000 further comprises a motor drive circuit 221020 which isconfigured to control the electric motor, as described in greater detailbelow. In various instances, the control circuit 221000 forms a part ofanother control circuit of the surgical instrument. For example, thecontrol circuit 221000 can form a part of the control circuit whichincludes a main processing circuit and/or main processor of the surgicalinstrument, and/or one or more memory devices, for example.

The acoustic sensor 221002 is configured to sense acoustic information,in the form of vibration energy, associated with an electric motor221012, gearboxes 221014, 221016 operably coupled to the motor 221012,and/or a drive train 221018 operably coupled with the gearboxes 221014,221016. The electric motor 221012, the gearboxes 221014, 221016 and thedrive train 221018 collectively form a drive system of the surgicalinstrument. Thus, the acoustic sensor can be considered as beingconfigured to measure a parameter of the drive system of the surgicalinstrument. In various instances, the acoustic sensor 221002 comprises apiezoelectric pickup, for example, responsive to the acoustic forcestransmitted by the soundwaves emitted from the motor 221012, thegearboxes 221014, 221016, and/or the drive train 221018. The acousticsensor 221002 is configured to convert the mechanical energy from thesound waves into electrical energy in the form of electric signals orvoltage potentials within the circuitry of the acoustic sensor 221002.Notably, the acoustic information sensed by the acoustic sensor 221002is not limited to vibrations within the range of human hearing.Vibrations above or below the range of human hearing can also be sensedby the acoustic sensor 221002 and converted into electrical energy.

Further to the above, the gearboxes 221014, 221016 comprise speedreduction gearboxes configured to produce a rotational output which isslower than the output speed of the electric motor 221012. As a result,the electric motor 221012 and the drive train 221018 rotate at differentspeeds and, accordingly, have different acoustic signatures. The inputof the first gearbox 221014 rotates at the speed of the electric motor221012 while the output of the first gearbox 221014 rotates at a slowerspeed than the electric motor 221012 and, as such, the first gearbox221014 has a different acoustic signature than the electric motor221012. Similarly, the input of the second gearbox 221016 rotates at thespeed of the first gearbox 221014 output and the output of the secondgearbox 221016 rotates at a different speed than its input. As such, thesecond gearbox 22106 has a different acoustic signature than the firstgearbox 221014. Each of these acoustic signatures has a frequencycontent, including wavelength and amplitude/magnitude, which is relatedto the speed of the respective component.

The signal conditioner 221004 is configured to receive the acousticinformation (e.g., electric signals or voltage potentials) from theacoustic sensor 221002 and convert the acoustic information into anothertype of electrical signals. For example, in various instances, thesignal conditioner 221004 may amplify the magnitude of the electricalsignals from the acoustic sensor 221002, filter out noise within theelectrical signals from the acoustic filter 221002, etc. The fastFourier transform (FFT) circuit 221006 executes a FFT algorithm whichanalyzes the electrical signals from the signal conditioner 221004 andconverts the electrical signals from a time domain to a representationin the frequency domain. In various instances, a main processing circuitof the surgical instrument can execute the FFT algorithm. The convertedelectrical signals may be considered frequency component signals. Thefrequency-to-voltage converter 221008 is configured to convert thefrequency component signals provided by the FFT circuit 221006 to aproportional voltage signal. The proportional voltage signal is used asa feedback signal which is input into the summing amplifier 221010. Thesumming amplifier 221010 compares the proportional voltage signal to amotor speed command signal (which is a voltage signal) provided by amotor controller 221018, and adjusts the motor speed command signal asneeded. For example, if the proportional voltage signal from thefrequency-to-voltage converter 221008 is the same as the motor speedcommand signal provided by the motor controller 221018, no adjustment ofthe motor speed command signal is needed. However, if the proportionalvoltage signal from the frequency-to-voltage converter 221008 isdifferent from the motor speed command signal provided by the motorcontroller 221018 (e.g., less than or greater than), the summationamplifier 221010 will increase or decrease the motor speed commandsignal so that the motor can realize the desired speed of rotation. Theadjusted motor speed command signal is passed to the motor drive circuit221020, which operates to provide a voltage to the motor, where thevoltage varies in accordance with a desired speed of rotation of themotor as called for by the adjusted motor speed command signal. Invarious instances, the motor controller 221018 and/or the motor drivecircuit 221020 are part of the control circuit 221000, or they cancomprise separate circuits in communication with the control circuit22100. In certain instances, the motor controller 221018 and/or themotor drive circuit 221020 are part of a control circuit which includesthe main processor of the surgical instrument.

Further to the above, the control circuit 221000 is configured todiscern between the different acoustic signatures of various electricmotors, gearboxes, and/or drive trains of the surgical instrument usinga single acoustic sensor. In various other instances, the controlcircuit 221000 can comprise a plurality of acoustic sensors 221002. Inat least one such instance, each acoustic sensor 221002 is exclusivelydedicated to pick up the acoustic waves of a single component of thesurgical instrument, such as an electric motor, gearbox, or drive train,for example. In any event, baselines for the respective acousticsignatures of the rotatable components of a surgical instrument can beestablished during the assembly of the surgical instrument, and suchbaselines serve as references for the control circuit 221000 toassociate the sensed acoustic signatures with the correct componentsand, also, determine whether or not the surgical instrument is operatingnormally. Moreover, by utilizing one or more acoustic sensors 221002 inthis way, the speed of a motor and/or gearbox can be sensed/measured,the start of travel by a translatable member can be detected, and/or theend of travel by the translatable member can be detected during use, forexample.

In various instances, further to the above, utilizing acousticinformation allows for the remote sensing of motor speed, therebyeliminating the need for directly coupled sensors and/or encoders, forexample. In various instances, the cost of the acoustic sensor 221002can be considerably less than an encoder and the assembly, wiring, andelectronics to support the encoder. Moreover, the acoustic sensor 221002and the FFT circuit 221006 can be part of a redundant system thatconfirms readings from other systems. Such an arrangement can be usefulfor mitigating risks and can create single point failure tolerantdesigns, for example. Furthermore, as indicated above, the acousticsensor 221002 and the FFT circuit 221006 can provide various indicationsof failure, wear, etc. of the drive components of the surgicalinstrument. Additional details regarding the detection of drive trainfailure can be found, for example, in U.S. patent application Ser. No.15/131,963, entitled METHOD FOR OPERATING A SURGICAL INSTRUMENT, filedApr. 18, 2016, now U.S. Patent Application Publication No. 2017/0296173,the disclosure of which is hereby incorporated by reference in itsentirety. The entire disclosure of U.S. patent application Ser. No.15/043,289, entitled MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILUREIN POWERED SURGICAL INSTRUMENTS, filed on Feb. 12, 2016, now U.S. PatentApplication Publication No. 2017/0231628 is incorporated by referenceherein.

Although the control circuit 221000 was described above in terms of theacoustic sensor 221002, it should be appreciated that other parametersof a surgical instrument can be sensed/measured to provide motor speedcontrol. For example, an accelerometer and/or vibration sensor, forexample, can be utilized in addition to or in lieu of the acousticsensor 221002 to sense/measure acceleration data, vibration data, etc.associated with a motor-driven system of the surgical instrument. Suchdata can be utilized to control the speed of rotation of the motor, asdescribed in greater detail below.

Further to the above, the functionality of the control circuit 221000 isutilized to implement one or more methods for identifying thedegradation and/or failure of the drive components of the surgicalinstrument. Such drive components include, for example, the motor221012, the first gearbox 221014, the second gearbox 221016, and/or thedrive train 221018 which can include a rack and pinion 221022 (see FIG.115) arrangement, for example.

FIG. 113 illustrates a method 221100 for identifying the degradation orfailure of components of a surgical instrument. As an initial step,i.e., step 221102, baseline measurements of the respective acousticsignatures of the motor 221012, the first gearbox 221014, the secondgearbox 221016, and/or the drive train 221018 are made. At step 221104,the FFT circuit 221006 produces the frequency component signals whichare representative of the baseline measurements of the respectiveacoustic signatures. This sequence may be repeated any number ofdifferent times for various speed and load conditions. Referring to FIG.114, a graph 221200 shows, in at least one instance, the frequencycomponent signals representative of the baseline measurements of therespective acoustic signatures broken down by component. Morespecifically, the graph 221200 shows the frequency profile 221012 a forthe motor 221012, the frequency profile 221014 a for the first gearbox221014, the frequency profile 221016 a for the second gearbox 221016,and the frequency profile 221018 a for the drive train 221018. Asillustrated in the composite frequency profile in FIG. 114, none of thefrequency profiles 221012 a, 221014 a, 221016 a, and 221018 a overlapwith one another; however, circumstances can arise where there is apartial overlap between adjacent frequency profiles. These frequencyprofiles, or their respective component signals, are recorded and storedon one or more memory devices, such as solid state memory devices, forexample, of the control circuit which includes the main processor of thesurgical instrument. The stored frequency profiles can be accessed bythe control circuit 221000. As explained in greater detail below, the“baseline” frequency component signals are utilized to determine if themotor-drive system of the surgical instrument has experienced anydegradation or failure.

After the baseline frequency component signals have been established andrecorded at step 221404, the surgical instrument is thereafter operatedand the frequency profiles of the acoustic signatures associated withsuch operation of the surgical instrument are determined and monitoredduring the operation of the surgical instrument at step 221106. Thefrequency profiles associated with the operation of the surgicalinstrument can be monitored by the control circuit 221000 and/or thecontrol circuit which includes the main processor of the surgicalinstrument. At step 221018, the frequency profiles are converted totheir respective frequency component signals by the FFT circuit 221006.At step 221110, the respective frequency component signals from step221108 are compared to the baseline frequency component signals fromstep 221104 to determine whether any of the components of themotor-driven system have experienced any degradation. This comparisoncan be implemented by the control circuit 221000, by the control circuitwhich includes the main processor of the surgical instrument and/or analgorithm of the surgical instrument, for example. As shown in the graph221300 of FIG. 115, the frequency component signal of the second gearbox221016 indicates possible fatigue and/or damage to the second gearbox221016 as it deviates from the baseline established at step 221404. Itshould be understood that a certain amount of deviation from theestablished baseline is to be expected, or normal, and thus notindicative of degradation and/or failure. To this end, the controlcircuit 221000, the control circuit which includes the main processor ofthe surgical instrument and/or the algorithm utilizes one or morepredetermined thresholds for delineating between a non-consequentialdeviation from the baseline and a consequential deviation from thebaseline.

Although the method 221100 was described in the context of determiningthe degradation or failure of the motor 221012, the first gearbox221014, the second gearbox 221016, and/or the drive train 221018, itshould be appreciated that the method 221100 could also be utilized todetermine the degradation or failure of other components of the surgicalinstrument.

FIG. 116 illustrates a method 221400 for identifying the degradation orfailure of the drive components of a surgical instrument. As an initialstep, baseline measurements of the current being drawn by the motor221012 are made over time at step 221402. The baseline currentmeasurements can be made in any suitable manner, such as by a currentsensor circuit, for example, and can provide an indication of the amountof current being drawn by the motor 221012 when the motor-driven systemof the surgical instrument is operating in a normal manner, i.e., whenthe motor 221012, the gearboxes 221014 and 221016, and the drive train221018 have not yet experienced any degradation and/or damage. At step221404, a FFT circuit, which can be similar or identical to the FFTcircuit 221006, produces frequency component signals which arerepresentative of the baseline measurements of the current being drawnby the motor 221012. This sequence may be repeated any number ofdifferent times for various speed and load conditions. As explained ingreater detail below, the “baseline” frequency component signals can beutilized to determine if the motor-drive system of the surgicalinstrument has experienced any degradation or failure.

After step 221404, the current being drawn by the motor 221012 issensed/measured by the current sensor circuit, for example, at step221406, and converted to the respective frequency component signals bythe FFT circuit at step 221408. At step 221410, the respective frequencycomponent signals from step 221408 are compared to the baselinefrequency component signals from step 221404 to determine whether any ofthe components of the motor-driven system have experienced anydegradation. This comparison can be implemented by the control circuit221000, by the control circuit which includes the main processor of thesurgical instrument and/or an algorithm of the surgical instrument, forexample. In various instances, the control circuit 221000, the controlcircuit which includes the main processor of the surgical instrumentand/or the algorithm look for repetitious events on a frequency whichcould be indicative of a spinning failure such as, for example, achipped tooth on a gear of a gearbox.

Referring to FIG. 117, a graph 221500 shows the baseline measurements221502 (solid line) and the subsequent measurements 221504 (dashed line)of the current drawn by the motor 221102. The graph 221500 also showsthe baseline frequency component signals 221506 (forward slash bars) andthe subsequent frequency component signals 221508 (back slash bars)representative of the baseline measurements and the subsequentmeasurements of the current drawn by the motor 221102. The graph 221500includes two horizontal axes—an “upper” horizontal axis 221510 and a“lower” horizontal axis 220512. The time t is shown along the “upper”horizontal axis 221510, and the frequency Hz is along the “lower”horizontal axis 221512. The graph 221500 also includes two verticalaxes—an “upper” vertical axis 220514 and a “lower” vertical axis 221516.The current is shown along the “upper” vertical axis 220514 and themagnitude of the fast Fourier transforms is shown along the “lower”vertical axis 221516. As discussed below, this information is used bythe control circuit 221000, the control circuit which includes the mainprocessor of the surgical instrument and/or an algorithm of the surgicalinstrument to evaluate repetitive anomalous current draws and/oracoustic events.

Referring again to FIG. 117, the subsequent current measurementsrepresented by the dashed line 221504 indicate three different instancesof an abnormal event being experienced by the motor 221012. Theseabnormal events comprise spikes in the motor current draw and arerepresented by three peaks in the dashed line 221504. The controlcircuit 221000, the control circuit which includes the main processor ofthe surgical instrument and/or the algorithm operate to differentiatebetween the baseline current draw and the anomalous current draw peaks.In at least one instance, the algorithm determines that an anomalouscurrent draw peak has occurred when the current draw exceeds a thresholddifference relative to the baseline current draw. In various instances,the threshold difference is 50% above the baseline current draw, forexample. In other instances, the threshold difference is 100% above thebaseline current draw, for example, although any suitable threshold canbe used. In various instances, the algorithm can use the motor currentdraw threshold alone to determine whether an anomalous event hasoccurred. In certain instances, the algorithm can use other parametersin addition to the motor current draw threshold for assessing anomalousevents. For instance, the algorithm can use the time between theanomalous events to determine whether or not the anomalous events arerepetitive. If a repeating time period between the repeating events canbe established by the algorithm, then the algorithm can determine thatthere may be degradation and/or damage in one of the rotating componentsin the drive system even though the current peaks do not exceed thethreshold. That said, the lack of an established time period between therepetitive events does not necessarily indicate that degradation and/ordamage hasn't occurred. Instead, in such instances, it can be an earlyindication of degradation and/or damage. In at least one instance, thethreshold for determining whether motor current draws are abnormal islower if a consistent time period between the peaks can be established.Correspondingly, the threshold is higher if a consistent time periodcan't be established.

Notably, the above-discussed anomalous current draws may or may notcorrespond with a corresponding variation in the baseline acousticfrequency profile. For instance, in FIG. 117, the frequency componentsof the baseline current and the subsequent current are within the normalexpected range during the three motor current spikes discussed above,which is shown in three grouping comparisons 221518 delineated by dashedlines. If, however, there is also an anomalous repetitive event withinthe frequency components that corresponds in time with the measuredmotor current peaks, the algorithm can apply a lower threshold fordetermining anomalous motor current draws indicative of drive componentdegradation and/or damage. The above being said, an anomalous repetitiveevent within the frequency components without corresponding motorcurrent spikes can also be indicative of drive component degradationand/or damage. FIG. 117 depicts such an abnormal additional frequency221520. When the magnitude of the anomalous frequency exceeds apredetermined threshold, the algorithm can determine that degradationand/or damage has occurred. In various instances, the algorithm can usea lower threshold for the frequency magnitude when corresponding motorspikes are present and a higher threshold for the frequency magnitudewhen corresponding motor spikes are not present. As such, the algorithmcan determine that degradation and/or damage has occurred with orwithout corresponding anomalous motor current draws, and vice versa.

Although the method 221400 of FIG. 116 was described in the context ofdetermining the degradation or failure of the motor-driven system basedon a comparison of currents being drawn by the motor 221012, it will beappreciated that similar methods which utilize other comparisons couldalso be utilized to determine the degradation or failure of the drivecomponents of the surgical instrument. For example, a measured motorload could be compared to measured shaft power over time, and changes inlosses between the two can be utilized to identify possible fatigueand/or damage to a component of the motor-drive system of the surgicalinstrument. Additionally, methods similar to those of the method 221100and/or the method 221400 can be utilized for purposes of heat managementwithin a sterile barrier of the surgical instrument.

FIG. 118 illustrates a method 221600 for adjusting a motor controlalgorithm of a surgical instrument. An algorithm refers to aself-consistent sequence of steps leading to a desired result, where a“step” refers to a manipulation of physical quantities, which may takethe form of electrical or magnetic signals capable of being stored,transferred, combined, compared, and otherwise manipulated. In thecontext of the motor control algorithm, the motor control algorithm isutilized to control the speed of a motor of the surgical instrument. Themethod 221600 may be utilized to adjust the motor control algorithm tominimize or limit damage of a drive whenever degradation or failure ofthe drive has been detected. Prior to the start of the method 221600,the method 221100, the method 221400, and/or similar methods can beutilized to detect the degradation and/or damage of the motor-drivensystem.

If degradation or failure is detected, referring again to FIG. 118, acontrol circuit of the surgical instrument (e.g., the control circuitwhich includes the main processor of the surgical instrument) adjuststhe motor control algorithm to adjust or control the speed of theelectric motor at step 221602 to try to reduce the noise, vibration,and/or wear on a component of the motor-drive system. In variousinstances, the speed control can be adjusted by adjusting the pulsewidth modulation (PWM) duty cycle to speed up or slow down the motorspeed given an experienced torque (load) on the system. Adjusting thePWM duty cycle to increase the voltage of the motor speed command signalprovided by the motor controller operates to increase the voltageapplied to the motor, which in turn operates to increase the motorspeed. Adjusting the PWM duty cycle to decrease the voltage of the motorspeed command signal provided by the motor controller 221018 operates todecrease the voltage applied to the motor, which in turn operates todecrease the motor speed. Decreasing the motor speed allows for theacoustic sensing of the motor-drive system to be moved to lowerfrequency levels. Increasing or decreasing the motor speed can move theoperation of the motor drive system away from the natural resonance, ornatural frequency harmonics, of the motor drive system.

After the PWM duty cycle has been adjusted at step 221602, the motordrive system is checked once again at step 221604 to determine whetheror not any degradation or failure of the motor drive system hasoccurred. The determination can be made by utilizing the method 221100,the method 221400, and/or similar methods. In various instances, suchdeterminations are made on a periodic basis, or on a continuous basis,whenever the motor drive system is in use. If degradation or failure isdetected at step 221604, the control circuit adjusts the motor controlalgorithm to adjust a current limit of the motor controller at step221606 proportionate to the detected wear level of the motor-drivesystem to try to minimize the likelihood of further wear or catastrophicfailure. By lowering the amount of current available to be drawn by themotor, the force or torque applied/delivered by the motor is alsolimited. Thus, by lowering the current limit of the motor controllerproportionate to the detected wear level of the motor drive system, thepower of the motor is decreased commensurate with the detected wearlevel of the motor-drive system.

After the current limit of the motor controller 221108 has been adjustedat step 221606, the motor-drive system is checked once again at step221608 to determine whether or not any degradation or failure of themotor-drive system has been detected. The determination can be made byutilizing the method 221100, the method 221400 or similar methods. Invarious instances, such determinations are made on a periodic basis, oron a continuous basis whenever the motor-drive system is in use.

If degradation or failure is detected at step 221608, the controlcircuit adjusts the motor control algorithm to oscillate adjustment ofthe speed control of the surgical instrument or the current limit of themotor controller at step 221610 to coincide with a detected failingpoint of the motor-drive system to try to compensate for the detecteddamage. For example, if a tooth on a gear has failed, is cracked, or ispartially damaged, the acoustic sensor 221002 could detect the clatterresulting from the damage. The decomposition provided by a fast Fouriertransform circuit, such as the fast Fourier transform circuit 221006,for example, could define the period of the disturbance, and then themotor control algorithm could adjust the current limit of the motorcontroller, the motor speed command signal (a voltage) provided by themotor controller, and/or the PWM duty cycle synchronized to that periodto reduce overall system vibration and further overstress of themotor-driven system.

After the speed control of the surgical instrument and/or the currentlimit of the motor controller has been adjusted in an oscillating mannerat step 221610, the motor drive system is checked once again at step221612 to monitor the degradation and/or failure of the motor drivesystem. This determination can be made by utilizing the method 221100,the method 221400, and/or similar methods. Such determinations are madeon a periodic basis, or on a continuous basis whenever the motor-drivesystem is in use. If additional degradation or failure is detected atstep 221612, the above-described process can repeat itself, and can berepeated any number of times. If degradation or failure is detected atstep 221612 which exceeds a threshold, as described in greater detailbelow, the process may end. Although a specific order of steps has beendescribed for the method 221600, it will be appreciated that the orderof the steps can be different. For example, the current threshold can beadjusted before the speed control is adjusted and/or at the same timethat the speed control is adjusted.

If a motor-driven system failure initiates during a surgical procedurebut the motor-drive system or a component thereof does not entirelyfail, the motor control algorithm can operate to reduce the performanceof the motor-drive system (e.g., speed, capability, load) to allow theclinician to continue without delaying the surgical procedure and allowfor a different surgical instrument to be obtained. Responsive to thepartial failure, the control circuit and/or an algorithm can generateone or more warnings to the user. Such warnings can be in the form of anaudible warning, a visual warning, a tactile warning, and/orcombinations thereof, for example, and can indicate that the surgicalinstrument will experience an impending failure, is being operated in alimp mode, and/or will need to be serviced soon, for example. Thecontrol circuit and/or the algorithm could also include a countdown as apercent of damage, time since damage, and/or performance degradation tohelp the clinician know how much time is remaining until servicing ofthe surgical instrument is required.

Further to the above, the control circuit and/or the algorithm canprovide an assessment regarding the severity of the failure. Theassessment can inform multiple decision outcomes that ensure patientsafety while balancing the delay to the procedure and/or the cost ofusing another surgical instrument, for example. If the severity of thefailure is deemed catastrophic by the control circuit and/or thealgorithm, the control circuit and/or the algorithm can inform theclinician of the determination by an appropriate feedback generator. Ifthe severity of the failure is deemed nearly catastrophic such that aprocedure step cannot be completed, the control circuit and/or thealgorithm can operate to inform the user that the user must pursueappropriate steps to safely release the surgical instrument from thepatient. When the surgical instrument is a motor-driven tissue cuttingstapling instrument, for example, the control circuit and/or thealgorithm can operate to only allow the drive motor to reverse the knifedirection, if possible, and/or revert to manual bailout to retract theknife. If the severity of the failure is deemed severe damage, but notcatastrophic, the control circuit and/or the algorithm can operate toinform the clinician of the damage level and allow the clinician tocomplete the procedure step, but disable use of the surgical instrumentafter the procedure step is complete and the surgical instrument issafely removed from the patient. If the severity of the failure isdeemed damaged, but not severely, the control circuit and/or thealgorithm can operate to inform the clinician that damage has occurredand that functionality of the surgical instrument may be altered, butthat it is possible to continue the procedure beyond the currentprocedural step.

In various instances, the control circuit and/or an algorithm isconfigured to use situational awareness to perform a risk assessment ofa damaged surgical instrument and the remaining procedure steps toinform the clinician of a recommended course of action. In a bariatricprocedure, for example, a surgical stapling and cutting instrument isused to transect and staple a portion of a patient's stomach. Notably,stomach tissue can vary in thickness along the transection and staplingpath. In fact, the tissue thickness variation along this path is usuallyquite predictable. In a revisional bariatric procedure removing agastric band, for example, the first stapling firing of the surgicalstapling and cutting instrument is on the antrum of the stomach, i.e.,where the stomach tissue is thickest. In such instances, as a result,the drive train of the surgical stapling and cutting instrument willlikely experience a high loading, stress, and strain during this firststapling firing. Thus, if the instrument is damaged in some way beforethis first stapling firing, it is possible that the first staplingfiring may further damage, if not catastrophically damage, theinstrument. With this in mind, in various instances, the surgicalinstrument comprises a wireless and/or wired signal transmitter andreceiver that is in communication with a surgical hub system and isconfigured to receive a notification from the surgical hub system thatthe surgical instrument is about to be used in this type of bariatricprocedure. In such instances, the control circuit and/or an algorithm isconfigured to inform the user of the surgical instrument of the damagedcondition of and/or the current damage to the surgical instrument andthe possibility of further damage. Moreover, the control circuit and/orthe algorithm can be configured to limit the current available to theelectric motor so as to reduce the possibility of catastrophic failureand optionally allow the clinician to override the lower current limit.The control circuit and/or algorithm can be further configured tore-evaluate the condition of the drive system of the surgical instrumentafter this first stapling firing for additional damage. If the currentdamage is still below an acceptable threshold, the control circuitand/or the algorithm can allow the subsequent staple firings of thesurgical instrument needed to complete the tissue incision and staplingpath. If the current damage is above the acceptable threshold, thecontrol circuit and/or the algorithm can recommend that the surgicalinstrument be replaced to complete the procedure. Thus, as a result ofdata from the surgical hub system, the instrument is situationally awareof the tissue thickness, density, and/or quality that is about to betransected and stapled. Moreover, the data from the surgical hub systemcan include data regarding previous surgical procedures involving thestomach tissue such as the presence of previous stapling lines, thepresence of the gastric band, and/or tissue scarring which, whentransected and stapled by the instrument, may increase the stress on theinstrument drive system. The control circuit and/or the algorithm canoperate in a similar manner to the above-described process to assess thecurrent degradation or damage of the instrument drive system, notify theclinician of this degradation or damage, and offer options to theclinician as how to proceed further in the surgical procedure.

Additional details regarding situational awareness are described, forexample, in U.S. patent application Ser. No. 15/940,654, entitledSURGICAL HUB SITUATIONAL AWARENESS, filed on Mar. 29, 2018, thedisclosure of which is herein incorporated by reference in its entirety.

In various instances, the condition of the motor-driven system iscommunicated to a surgical hub system on a periodic basis, or on acontinuous basis. Thus, the condition of the motor-driven system priorto a detected failure is known by the surgical hub system. A surgicalhub system is described in more detail in U.S. patent application Ser.No. 15/940,629, entitled COMPUTER IMPLEMENTED INTERACTIVE SURGICALSYSTEMS, filed on Mar. 29, 2018, the disclosure of which is herebyincorporated by reference in its entirety. An algorithm, executed by acontrol circuit and/or processor of the surgical hub system, can utilizethe history of the use of the surgical instrument in the current case,the life history of the surgical instrument and the surgical hub'ssituational awareness to more fully diagnose the potential for failureof the surgical instrument in the current case, an actual failure of thesurgical instrument in the current case, and better predict similarfailures in similar surgical instruments used in other cases. It will beappreciated that the knowledge provided by the functionality of thesurgical hub system can provide a better understanding of the failuremode, allow for future failures to be predicted and/or avoided based onthe data and analysis, and provide direction to design improvements ofthe surgical instrument to improve lifecycles and avoid future failures.When the surgical hub system determines a failure of a surgicalinstrument is impending, the surgical hub system can communicate thisinformation to a user of the surgical instrument via a display and/or aspeaker of the surgical hub system.

In various instances, a handle of the surgical instrument can beconfigured to provide the electrical system within the handle withimproved durability and robustness to the surgical environment. Forexample, touch-less controls which can be entirely sealed and whichrequire no force to cause a switch of state can be incorporated into thedesign of the handle. Also, reusable handles can be provided withimproved replaceable switch and control elements.

In many surgical procedures, more than one surgical instrument isutilized to complete the surgical procedure. In many instances, at leasttwo surgical instruments can be positioned within the patient at thesame time, and it is possible for the two surgical instruments to comeinto contact and/or close proximity with one another. In somecircumstances, this does not cause a major concern. In othercircumstances, such as when one of the surgical instruments is anelectrosurgical instrument or an ultrasonic surgical instrument, forexample, it is desirable to keep another surgical instrument from cominginto contact with the electrosurgical instrument or the ultrasonicsurgical instrument.

FIG. 119 illustrates an environment 222000 of a surgical procedure. Theenvironment 222000 includes a first surgical instrument 222002, a secondsurgical instrument 222004, a patient 222006, and a grounding pad 222008in contact with the patient 222006. The first and second surgicalinstruments 222002, 222004 are shown as positioned within the patient222006, i.e., within an abdominal cavity, for example, who is lying onthe grounding pad 220008. The first surgical instrument 222002 can beany of a variety of different surgical instruments. For example, thefirst surgical instrument 222002 can be an endocutter, or a tissuecutting and stapling instrument, comprising a shaft 222010 and an endeffector comprising jaws 222012. An external surface of the shaft 222010and/or the jaws 222012 of the endocutter 222002 includes an electricallyconductive material such as, for example, a stainless steel and/or anyother suitable metal.

The second surgical instrument 222004 is a monopolar instrument whichcan receive high-frequency electrosurgical energy from a source, andapply the high-frequency electrosurgical energy to the patient 222006 ina manner well-known in the art. For example, the high-frequencyelectrosurgical energy is applied by an electrode tip 222013 of thesecond surgical instrument 222004. The source can be, for example, amonopolar generator such as the monopolar generator module 220310 of thesurgical hub 220302. Under normal circumstances, the electrosurgicalenergy applied to the patient 222006 passes through the patient 222006to the grounding pad 220008, where it is then returned back to thesource of the electrosurgical energy via electrical conductors of areturn path (not shown) to complete an electrosurgical electricalcircuit.

Due to the proximity of the first surgical instrument 222002 to thesecond surgical instrument 222004 within the patient 222006 at certaintimes during the surgical procedure, there is a risk that too much ofthe high frequency electrosurgical energy applied to the patient 222006by the second surgical instrument 222004 during the surgical procedurewill be diverted through the patient 222006 to the first surgicalinstrument 222002 owing to the high conductivity of the shaft 222010and/or the jaws 222012 as opposed to the grounding pad 222008 asintended. The closer the first surgical instrument 222002 comes to thesecond surgical instrument 222004 within the patient 222006, the higherthe risk of too much of the high frequency electrosurgical energypassing through the patient 222206 to the first surgical instrument222002. In a worst case scenario, where the electrically conductiveportion of the first surgical instrument 222002 comes into directcontact with the electrode tip of the second surgical instrument 222004,an electrical short-circuit is established from the second surgicalinstrument 222004 directly to the first surgical instrument 222002.

In order to mitigate the chance of too much of the high frequencyelectrosurgical energy passing through the patient 222006 to the firstsurgical instrument 222002, the second surgical instrument 222004 isconfigured to apply a low current to the patient 222006 as a testcurrent prior to the second surgical instrument 222004 applying the fulllevel of electrosurgical energy to the patient 222006. The source of thetest current can be, for example, a monopolar generator such as themonopolar generator module 220310 of the surgical hub 220302. In orderto apply the test current, the second surgical instrument 222004includes electrical terminations 222014 (see FIGS. 120, 121, and 122) onthe shaft 222018 of the second surgical instrument 222004. Theelectrical terminations 222014 are electrically connected to the sourceof the electrosurgical energy, and/or a battery, and can apply the testcurrent to the patient 222006. In a way, the electrical terminations222014 are being utilized as continuity sensors to help determineelectrical continuity along a path from the second surgical instrument222004, through the patient 222006, and to the grounding pad 222008.According to various aspects, the electrical terminations 222014 form aportion of a control circuit of the second surgical instrument 222004,and the control circuit and/or an algorithm can be utilized to apply thetest current to the patient 222006.

The test current may only be applied for a brief period of time, such asfor a few milliseconds, for example, in order to adequately determine ifa sufficient instrument-patient-pad continuity is present as describedabove. According to various aspects, the continuity can be determined bya sensing device incorporated into the grounding pad 222008, a sensingdevice incorporated in the cord or cable of the return path and/or by amonopolar generator such as the monopolar generator module 220310 of thesurgical hub 220302. Moreover, the test current may comprise an amperageof only a few milliamps, for example. If the application of the testcurrent does not indicate the presence of a short circuit or significantshunt between the first surgical instrument 222002 and the secondsurgical instrument 222004, the control circuit operates to allow thesecond surgical instrument 222004 to be provided with the full level ofelectrosurgical energy which can then be applied to the patient 222006.However, if the application of the test current indicates the presenceof a short circuit or significant shunt between the first surgicalinstrument 222002 and second surgical instrument 222004, the controlcircuit operates to prevent the second surgical instrument 222004 frombeing provided with the full level of electrosurgical energy,effectively preventing or locking out the second surgical instrument222004 from applying the full level of electrosurgical energy to thepatient 220006 until the instruments 222002 and 222004 are sufficientlyseparated to eliminate the short circuit or shunt therebetween.According to various aspects, the test current can also be appliedperiodically or continuously throughout a surgical procedure, and theelectrosurgical energy being applied to the patient 222006 during thesurgical procedure can be decreased or even interrupted based on thesensing and/or detection of short-circuits and/or significant shuntsbetween the first surgical instrument 222002 and the second surgicalinstrument 222004.

Referring to FIGS. 120-122, the signals 222016 shown as being emittedfrom the electrical terminations 222014 are representations of the testcurrent exiting from the electrical terminations 222014. Although theelectrical terminations 222014 are only shown as being positioned on theshaft 222018 of the second surgical instrument 222004, the electricalterminations 222014 are also positioned on the body 222020 of the secondsurgical instrument 222004. Such an arrangement provides for potentialleakage paths from the body 222020 of the second surgical instrument222004 to the shaft 222010 and/or jaws 222012 of the first surgicalinstrument 222002, as well as from the shaft 222018 of the secondsurgical instrument 222004 to the shaft 222010 and/or jaws 222012 of thefirst surgical instrument 222002, for example.

FIG. 123 illustrates a graph 222100 which shows a relationship betweenthe leakage current 222102 of the surgical instrument 222004 and theproximity of other objects in the surgical environment 222000 to thesurgical instrument 222004. The time t is shown along the horizontalaxis 222104 and the leakage current is shown along the vertical axis222106. When nothing but air is within approximately 5 centimeters fromthe second surgical instrument 222004, there is very little, if any,current loss from the second surgical instrument 222004. In fact, thecurrent loss in such instances is below a first threshold which can beinterpreted by the control circuit of the surgical instrument 222004that the surgical instrument 222004 is not in contact with the patientor another surgical instrument. The surgical instrument 222004 furthercomprises a first indicator, such as a light and/or a symbol on a screenof the surgical instrument 222004, for example, in communication withthe control circuit that, when actuated by the control circuit,indicates to the clinician that the surgical instrument 222004 is not ina position in which it can affect the patient tissue and/or short outagainst and/or contact another surgical instrument, for example. In atleast one instance, the first indicator comprises a green LED, forexample.

When the surgical instrument 222004 is moved close to the patient,referring again to FIG. 123, the leakage current increases above thefirst threshold. In at least one such instance, close can beapproximately 3 cm, for example. The surgical instrument 222004 furthercomprises a second indicator, such as a light and/or a symbol on ascreen of the surgical instrument 222004, for example, in communicationwith the control circuit that is activated by the control circuit whenthe leakage current exceeds the first threshold. In at least oneinstance, the second indicator comprises a yellow LED, for example. Theactuation of the second indicator indicates to the clinician that thesurgical instrument 222004 may be in a position in which it can affectthe patient tissue. Because the leakage current is still below a secondthreshold, however, a third indicator in communication with the controlcircuit, such as a light and/or a symbol on a screen of the surgicalinstrument 222004, for example, is not actuated. In such instances, theclinician can understand that the surgical instrument 222004 is not in aposition to short out against and/or contact another surgicalinstrument, for example. In at least one instance, the third indicatorcomprises a red LED, for example. When the surgical instrument 222004 isin contact with the patient, but not another surgical instrument, theleakage current is above the first threshold but still below the secondthreshold unless the surgical instrument 222004 is moved close toanother surgical instrument, as discussed below.

When the surgical instrument 222004 is moved close to another surgicalinstrument, referring again to FIG. 123, the leakage current increasesabove the second threshold. In at least one such instance, close can beapproximately 3 cm, for example. In such instances, the control circuitof the surgical instrument 222004 actuates the third indicator. In suchinstances, the clinician can understand that the surgical instrument222004 may be in a position to short out against and/or contact anothersurgical instrument, for example. When the surgical instrument 222004moves even closer to another surgical instrument, such as withinapproximately 1 cm, for example, the current leakage can increasesignificantly. In such instances, the control circuit can produce anaudible warning via a speaker in the surgical instrument 222004 incommunication with the control circuit, for example. Such an audiblewarning could also be created when the surgical instrument 222004contacts the other surgical instrument. If the surgical instrument222004 is moved away from the other surgical instrument and the leakagecurrent decreases, the control circuit will deactivate the audiblewarning. If the leakage current falls below the second threshold, thecontrol circuit will deactivate the third indicator. If the leakagecurrent falls below the first threshold, the control circuit willdeactivate the second indicator. As a result of the above, a cliniciancan understand the positioning of the surgical instrument 222004relative to its environment.

In order to mitigate false warnings of unwanted contact, it isbeneficial to establish thresholds which can be utilized todifferentiate contact between, one, the second surgical instrument222004 and the body of the patient 222006 or a trocar, two, the secondsurgical instrument 222004 and the target tissue of the patient 222006and, three, the second surgical instrument 222004 and the first surgicalinstrument 222002 or another surgical instrument within the environment222000 of the surgical procedure.

FIG. 124 illustrates a graph 222200 which shows the direct current (DC)output voltage 222202 of the test current of the second surgicalinstrument 222004 during a surgical procedure. The time t of thesurgical procedure is shown along the horizontal axis 222204 and thevoltage v of the test current is shown along the vertical axis 222206.At time t₁, the voltage 222202 of the test current crosses a v₁ voltagethreshold 222208 which is indicative of the second surgical instrument222004 coming into contact with the trocar as the second surgicalinstrument 222004 is inserted into the patient. The voltage v of thetest current then spikes upward for a brief period of time as thecontinuity sensors 222014 of the second surgical instrument 222014 arepassing through the trocar. Thereafter, the voltage of the test currentreturns back to the lower level once the sensors 222014 have passedthrough the trocar and the second surgical instrument 222004 is furtherinserted into the patient. At time t₂, the voltage 222202 of the testcurrent crosses a v₂ voltage threshold 222210 which is indicative of thesecond surgical instrument 222004 coming into contact with, or closeapproximation with, the tissue of the patient 222006. The voltage 222202thereafter stays above the v₂ voltage threshold 22210 as the surgicalinstrument 222004 is moved and manipulated relative to the patienttissue. At time t₃, the voltage 222202 of the test current crosses thev₃ voltage threshold 222212, which is indicative of the second surgicalinstrument 222004 coming into contact with, or close approximation with,the first surgical instrument 222004 or another surgical instrumentwithin the environment 222000 of the surgical procedure. The voltage222202 of the test current returns to a lower level as the secondsurgical instrument 222004 is moved away from the adjacent instrument.The v₁ voltage threshold 222208 can be considered aninstrument-to-trocar contact threshold, the v₂ voltage threshold 222210can be considered an instrument-to-target tissue contact threshold, andthe v₃ voltage threshold 222210 can be considered aninstrument-to-instrument contact threshold.

In various instances, a control circuit and/or an algorithm can beutilized to analyze the DC output voltage v on an ongoing or continuousbasis. The control circuit and/or the algorithm takes into account themagnitude of DC output voltage 222202, the slope of the DC outputvoltage 222202, and/or the rate of change of the slope of the DC outputvoltage 222202, for example. Using such data, the control circuit and/orthe algorithm can provide a more accurate indication of when the secondsurgical instrument 222004 actually comes into contact with a trocar orthe body of the patient 222006, the target tissue of the patient 222006,and the first surgical instrument 222002 or another surgical instrumentwithin the environment 222000 of the surgical procedure. The moreaccurate indication provided by the control circuit and/or the algorithmoperates to mitigate false warnings of unwanted contact.

Further to the above, various forms of current leakage or interactioncan occur between two or more surgical instruments in a surgicalenvironment. For example, when a fluid is present around a staplecartridge jaw of an endocutter positioned in a patient, an exposed setof electrical contacts of the endocutter can interfere with the sensingof an adjacent powered dissector. Therefore, it is desirable to senseand monitor the electrical interaction between adjacent powered surgicaldevices. In various instances, the electrical potential of one or morecircuit boards in a surgical instrument and/or the interconnected metalshaft components of a powered surgical instrument can be sensed andmonitored. In certain instances, the electric potential is sensed by thesource of the high frequency electrosurgical power. In at least oneinstance, the electrical potential is sensed by respective sensingdevices of the powered surgical instruments. Based on the sensedelectrical potentials, respective control circuits and/or algorithms ofthe powered surgical instruments can determine if any of the poweredsurgical instruments are bleeding current or have a parasiticinteraction and could be inadvertently exposing the adjacent surgicaldevices to false signals.

FIG. 125 illustrates a powered surgical instrument 222300. The shaft ofthe powered surgical instrument 222300 includes an electrical sensinggrid 222302 and electrical insulation 222304. The electrical sensinggrid 222302 is configured to detect electrical potential relative toground. The electrical insulation 222304 surrounds the electricalsensing grid 222302 and operates to electrically isolate the electricalsensing grid 222302 from the environment which is external to thepowered surgical instrument 222300. In at lest one instance, theelectrical sensing grid 222302 is sealed against the shroud of the shaftto prevent, or reduce the possibility of, fluids contacting the sensinggrid 222302.

FIG. 126 illustrates a graph 222400 which shows the electrical potential222402 associated with the powered surgical instrument 222300 of FIG.125, in accordance with at least one aspect of the present disclosure.The time t is shown along the horizontal axis 222404 and the electricalpotential v_(ext) is shown along the vertical axis 222406. The low valueof the electrical potential 222402 shown along the bottom left of thegraph 222400 is indicative of some parasitic or exposed current beingpresent between the electrical components which are internal to thepowered surgical instrument 222300. As the powered surgical instrument222300 comes closer to an external electrical source, such as anotherpowered surgical instrument, for example, the electrical potential222402 begins to increase. The electrical potential 222402 increasesmore and more as the powered surgical instrument 222300 gets closer andcloser to the external electrical source. The slope of the increasedelectrical potential, which is represented by the dashed line 222408,can be utilized to indicate the presence and/or proximity of theexternal electrical source. In various instances, a control circuitand/or an algorithm can be utilized to analyze the electrical potential222402, and taking into account the magnitude of the electricalpotential 222402, the slope of the electrical potential 222402, and/orthe rate of change of the slope of the electrical potential 222402, forexample, the control circuit and/or the algorithm can provide anaccurate determination of how close the powered surgical instrument222300 is to an external electrical source.

FIG. 127 illustrates an active transmission and sensing scheme 222500utilized by first and second surgical instruments 222502, 222504. Thefirst surgical instrument 222502 is a “smart” surgical instrument andincludes a transmitter 222506 (which can be a magnetic transmitter) anda receiving circuit 222508 which collectively operate to providemagnetic emission and detection along the shaft 222510 and/or the endeffector 222512 of the first surgical instrument 222502. The firstsurgical instrument 222502 comprises an endocutter including a staplecartridge jaw and an anvil jaw, but can comprise any suitable surgicalinstrument. The second surgical instrument 222504 is a “non-transmissionenabled” surgical instrument and includes first and second sensingdevices 222514, 222516 which are positioned opposite one another on theshaft or body 222518 of the second surgical instrument 222504. Thesecond surgical instrument 222504 comprises a clampable jaw and, inaddition, a blade in communication with a standing vibration transducerconfigured to cut and/or coagulate tissue. The first sensing device222514 is positioned on the “blade side” of the second surgicalinstrument 222504 while the second sensing device 222516 is positionedon the “jaw side” of the second surgical instrument 222504. The firstand second sensing devices 222514, 222516 are magnetic sensors, forexample. By being positioned opposite one another on opposite sides ofthe shaft or body 222518, the first and second sensing devices 222514,222516 allow for the first surgical instrument 222502 to determine theposition and orientation of the second surgical instrument 222504relative to the first surgical instrument 222502.

The transmitter 222506 and the receiving circuit 222508 extend along thelength of the shaft 222510 and/or the end effector 222512 of the firstsurgical instrument 222502. The transmitter 222506 and the receivingcircuit 222508 are positioned within a flexible circuit at any suitablelocation in the shaft 222510 and/or the end effector 222512, and can beactive at the same time, either continuously or intermittently, asdescribed in greater detail below. The transmitter 222506 is configuredto transmit a signal 222519 in the form of a magnetic field which isreflected by the first and second sensing devices 222514, 222516 of thesecond surgical instrument 222504 to form respective return signals222520, 222522, which are also in the form of magnetic fields. Thatsaid, signals other than magnetic fields could be emitted and reflectedin other aspects. The receiving circuit 222508 is configured to receivethe return signals 222520, 222522. According to various aspects, thereceiving circuit 222508 either incorporates or may be considered amagnetic sensing device. In various instances, the receiving circuit222508 is configured to look for a response from the transmitter 222506after the transmitter emits the signal 222519, as also described ingreater detail below.

In various instances, a magnetic power source of the transmitter 222506generates randomly sequenced on-off pulses. Stated another way, themagnetic fields emitted by the transmitter 222506 are not periodic;instead, the magnetic fields are emitted at random times as determinedby a control circuit and/or an algorithm of the first surgicalinstrument 222502. That said, the magnetic fields are emitted at anaverage rate of approximately 10 times per second and at a frequency ofaround 1 kHz, for example. Moreover, the duration of the magnetic fieldpulses are randomized. In between the pulses, the receiving circuit222508 can be switched in and is configured to listen for the returnsignals 222520, 222522. The receiver circuit 222508 receives the returnsignals 222520, 222522 and passes information representative of thereturn signals 222520, 222522 to a control circuit and/or an algorithmof the first surgical instrument 222502. The control circuit may alsohave information representative of the signals 222519 emitted by thetransmitter 222506. Based on the information representative of thesignals 222519 and the information representative of the return signals222520, 222522, the control circuit and/or the algorithm can determinethe position and orientation of the second surgical instrument 222504relative to the first surgical instrument 222502. If, for some reason,the receiver circuit 222508 only receives one of the return signals222520, 222522, the control circuit and/or the algorithm would be ableto determine the position of the second surgical instrument 222504relative to the first surgical instrument 222502, but not itsorientation.

In instances where another magnetic signal-emitting surgical instrumentis present in the surgical field of the first and second surgicalinstruments 222502, 222504, it is likely that the receiver circuit222508 of the first surgical instrument 222502 will receive the magneticsignals of the other signal-emitting surgical instrument. Without more,the control circuit and/or the algorithm may not be able to properlyanalyze the position and/or orientation of the second surgicalinstrument 222504 relative to the first surgical instrument 222502. Sucha situation could be avoided if the other signal-emitting surgicalinstrument emitted its signals at a frequency which can be filtered outby one or more low-pass and/or high-pass filters in the receiver circuit222508. Such a situation could also likely be avoided if the othersignal-emitting surgical instrument also emits a signal in the form of amagnetic field at an average rate of approximately 10 times per secondand at a frequency of around 1 kHz, for example. Owing to the randomnessof the pulse duration and rate of the signals emitted by the firstsurgical instrument 222502 and the other signal-emitting surgicalinstrument, and also to the randomness of switching in the receivercircuit 222508 and a corresponding receiver circuit in the othersignal-emitting surgical instrument, a situation where the magneticemissions from the two signal-emitting surgical instruments are inperfect synchrony is mitigated and/or avoided. Thus, it will beappreciated that the active transmission and sensing scheme 222500described above can also be utilized with two surgical instruments whichboth have active transmission and sensing means.

FIG. 128 illustrates a graph 222600 of signals transmitted and receivedby the first surgical instrument 222502 of FIG. 127. The transmittedsignals 222602 are representative of the signal transmitted by thetransmitter 222506 and are shown with back slashes. The received signals222604 are representative of the return signals 222520, 222522 and areshown with forward slashes. The time t is shown along the horizontalaxis 222608 and the amplitude of the transmitted and received signals222602, 222604 is shown along the vertical axis 222606. As shown in FIG.128, the amplitude of each of the transmitted signals 222602 is within agiven band relative to the 1 kHz emission frequency. The given amplitudeband is shown as being bounded by the dashed lines 222605A, 222605B.That said, the amplitudes of only some of the received signals 222604are within the given band. As described in more detail below, byanalyzing the difference between the transmitted signal 222602 and thereceived signal 222604 of each signal set and the differences betweeneach consecutive signal set, the control circuit and/or an algorithm ofthe first surgical instrument 222502 can determine the proximity andorientation of the second surgical instrument 222504 relative to thefirst surgical instrument 222502.

FIG. 129 illustrates a graph 222700 which shows the proximitymeasurements 222702 of the first sensing device 222514 and the proximitymeasurements 222704 of the second sensing device 222516 of the secondsurgical instrument 222504 relative to the first surgical instrument222502. The proximity measurements 222702 of the first sensing device222514 are shown with back slashes and the proximity measurements 222704of the second sensing device 222516 are shown with forward slashes. Thetime t is shown along the horizontal axis 222706 and the distance incentimeters is shown along the vertical axis 222708. According to thefirst set of “proximity bars” near the left-hand side of the graph222700 taken during a first sample, the second surgical instrument220504 is located somewhere around 10 centimeters relative to the firstsurgical device 222502 at a somewhat angled orientation. According tothe second set of “proximity bars” just to the right of the first settaken during a second sample, the second surgical instrument 220504 issomewhere within 7-9 centimeters of the first surgical device 222502 ata somewhat angled orientation. According to the third set of “proximitybars” just to the right of the second set taken during a third sample,the second sensing device 222516 positioned on the “jaw side” of thesecond surgical instrument 222504 is within 1 centimeter of the firstsurgical device 222502; however, the second surgical instrument 222504is angled at a steep angle relative to the first surgical instrument222502. According to the fourth set of “proximity bars” at theright-hand side of the graph 222700 which were taken during a fourthsample, the first sensing device 222514 positioned opposite the “bladeside” of the second surgical instrument 220504 is within 1 centimeter ofthe first surgical device 222502. As the proximities of both the firstand second sensing devices 222514, 222516 are determined relative to thefirst surgical instrument 222502, it will be appreciated that theorientation of the second surgical instrument 222504 relative to thefirst surgical instrument 222502 is also determined in this manner.

In addition to or in lieu of active sensing, passive sensing such asinductive sensing and/or capacitive sensing, for example, can beutilized to determine the proximity of one surgical instrument relativeto another surgical instrument.

FIG. 130 illustrates a passive sensing scheme 222800 utilized by a firstsurgical instrument 222801 and a second surgical instrument 222804. Thefirst surgical instrument 222802 includes a magnetic transmitter 222806and a transducer 222808. The transducer 222808 is configured to vary itsoutput voltage in response to a magnetic field. The transducer 222808comprises a Hall-effect sensor, but could comprise any suitable sensor.As described in more detail below, the Hall-effect sensor 222808 may beconsidered an inductive proximity sensor. The magnetic transmitter222806 operates to generate a primary magnetic field 222810 whichemanates outwardly from the magnetic transmitter 222806. When the secondsurgical instrument 222804 gets within a certain distance of the firstsurgical instrument 222802, the primary magnetic field 222810 induces acurrent in a conductive material of the second surgical instrument222804. In at least one instance, the shaft and/or a jaw of the secondsurgical instrument 222804, for example, comprises the conductivematerial. The induced current in the conductive material of the secondsurgical instrument 222804 operates to generate a secondary magneticfield 222812 which emanates out from the conductive material of thesecond surgical instrument 222804. The secondary magnetic field 222812tends to oppose the primary magnetic field 222810 and has a weakeningeffect on the primary magnetic field 222810. The net strength of themagnetic field at the Hall-effect sensor 222808, in both an unaffectedcondition (where the second surgical instrument 222804 is so far awayfrom the first surgical instrument 222802 so as to have no effect on theprimary magnetic field 222810) as well as in an affected condition(where the second surgical instrument 222804 is close enough to thefirst surgical instrument 222802 to have an effect on the primarymagnetic field 222810) is sensed by the Hall-effect sensor 222808, whichgenerates an output signal or Hall current representative of thestrength of the net magnetic field at the Hall-effect sensor 222808, andthus of the proximity of the second surgical instrument 222804 to thefirst surgical instrument 222802.

FIG. 131 illustrates the primary magnetic field 222810 in an unaffectedcondition proximate the Hall-effect sensor 222808. When there is noobject close enough to the first surgical instrument 222802 so as tohave an effect on the primary magnetic field 222810, the condition ofthe primary magnetic field 222810 is considered to be in an unaffectedcondition. Thus, the field lines 222814 shown in FIG. 130 may beconsidered representative of an unaffected condition of the primarymagnetic field 222810 and what is expected to be received by a receivingcircuit of the first surgical instrument 222802 absent the presence ofanother instrument.

FIG. 132 illustrates the primary magnetic field 222810 in an affectedcondition proximate the Hall-effect sensor 222808. When an object isclose enough to the first surgical instrument 222802 so as to have aneffect on the primary magnetic field 222810, the condition of theprimary magnetic field 222810 is considered to be in an affectedcondition. The field lines 222816 of the primary magnetic field 222810shown in FIG. 131, which are different from the field lines 222814 ofFIG. 130 and are shown as broken dashed lines, may be consideredrepresentative of an affected condition of the primary magnetic field222810, and are not what is expected to be received by a receivingcircuit of the first surgical instrument 222802.

FIG. 133 illustrates a graph 222900 which shows the Hall current 222902output by the Hall-effect sensor 222808 of the first surgical instrument222802 of FIG. 130. The strength of the net magnetic field sensed by theHall-effect sensor 222808, whether magnetic field strength H or magneticflux density B, is shown along the horizontal axis 222904, and thecurrent I is shown along the vertical axis 222906. As the strength ofthe net magnetic field sensed by the Hall-effect sensor 222808increases, the magnitude of the Hall current 222902 decreases. The highmagnitude of the Hall current 222902 shown along the left-had side ofthe graph 222900 is indicative of no other electrically conductiveobject, such as the second surgical instrument 222804, for example,being in close proximity to the first surgical instrument 222802. Thedecrease in the magnitude of the Hall-current between the 1 and the 2 ofthe magnetic field strength is indicative of the second surgicalinstrument 222804 being at some distance from the first surgicalinstrument 222802. The further decrease in the magnitude of theHall-current between the 2 and the 3 of the magnetic field strength isindicative of the second surgical instrument 222804 approaching thefirst surgical instrument 222802. The even further decrease in themagnitude of the Hall-current between the 3 and the 4 of the magneticfield strength is indicative of the second surgical instrument 222804being at close proximity to the first surgical instrument 222802. TheHall current can be passed to a control circuit of the first surgicalinstrument 222802, and the control circuit and/or an algorithm cananalyze the magnitude of the Hall current, the slope of the Hallcurrent, and/or the rate of change of the slope of the Hall current, forexample, to provide an indication of the proximity of the first surgicalinstrument 222802 to the second surgical instrument 222804.

FIGS. 134 and 135 illustrate a passive sensing scheme 223000 utilized bya first surgical instrument 223002 and a second surgical instrument223004. In this passive sensing scheme 223000, the first surgicalinstrument 223002 includes first and second capacitor plates 223006,223008 housed in a sensing head of the first surgical instrument 223002.In a parallel-plate capacitor arrangement like the one shown in FIGS.134 and 135, when a voltage is applied between the first and secondcapacitor plates 223006, 223008, a uniform electric field is createdbetween the first and second capacitor plates 223006, 223008. Thestrength of the electric field is directly proportional to the voltageapplied and inversely proportional to the distance between the first andsecond capacitor plates 223006, 223008. When there is no object closeenough to the first surgical instrument 223002 so as to have an effecton the electric field, the condition of the electric field is consideredto be in an unaffected condition. Thus, the field lines 223010 shown inFIG. 134 may be considered representative of an unaffected condition ofthe electric field and what is expected to be received by a receivingcircuit of the first surgical instrument 223002.

When an object is close enough to the first surgical instrument 222802so as to have an effect on the electric field, the condition of theelectric field is considered to be in an affected condition. As anotherelectrically conductive object, such as the second surgical instrument223004, for example, approaches the first surgical instrument 223002 asshown in FIG. 135, the capacitance associated with the first and secondcapacitor plates 223006, 223008 of the first surgical instrument 223002increases. The increased capacitance is shown conceptually by theadditional field lines 223012 in FIG. 135, and the electric field inFIG. 135 is different from the electric field in FIG. 134. The electricfield shown in FIG. 135 may be considered representative of an affectedcondition of the electric field, and is not what is expected to bereceived by a receiving circuit of the first surgical instrument 223002absent the presence of another surgical instrument. According to variousaspects, a sensing device such as a capacitive sensor can sense thecapacitance and generate an output signal representative of the sensedcapacitance. The output signal can be converted to a voltage signalwhich is representative of the sensed capacitance, and the voltagesignal can be passed to a control circuit of the first surgicalinstrument 223002. Based on the voltage signals which are representativeof the sensed capacitance, the control circuit and/or an algorithm canmonitor the sensed capacitances, and analyze the change in thecapacitance and/or the change in the electric field to provide anindication of the proximity of the first surgical instrument 223002 tothe second surgical instrument 223004. The capacitive sensor can thus beconsidered a capacitive proximity sensor.

In various aspects, instead of utilizing inductive proximity sensing orcapacitive proximity sensing as described above, a surgical instrumentmay utilize a different proximity sensing scheme. FIG. 136 illustrates asurgical instrument 223100 which includes a direct current (DC) powersource 223102, an oscillator 223104, a coil 223106, and a current sensor223108. The DC power source 223102 provides direct current (DC) power tothe oscillator 223104. The oscillator 223104 is configured to convertthe direct current (DC) power to an alternating current (AC) signalwhich is passed to the coil 223106. As the alternating current is fed tothe coil 22306, the coil 223106 generates a changing magnetic field223110 which induces a current in the coil 223106. The current from thecoil 223106 is sensed/measured by the current sensor 223108. As anelectrically conductive object, such as another surgical instrument, forexample, approaches the surgical instrument 223100, the other surgicalinstrument can affect the strength of the magnetic field 223110, whichin turn affects the magnitude of the induced current. Bysensing/measuring the induced current, a control circuit and/or analgorithm of the surgical instrument 223100 can determine when anotherobject is approaching and/or is in close proximity.

FIG. 137 illustrates a graph 223200 which shows the induced current223202 measured by the current sensor 223108 of the surgical instrument223100 of FIG. 136, in at least one instance. The time t is shown alongthe horizontal axis 223204, and the current I is shown along thevertical axis 223206. When the magnitude of the induced current 223202is relatively constant as shown for the period of time shown on theleft-hand side of FIG. 137, the induced current 223202 is indicative ofa situation where no other object/surgical instrument is approaching orproximate to the surgical instrument 223100. When the magnitude of theinduced current 223202 is increasing as shown for the period of timeshown on the right-hand side of FIG. 137, the induced current 223202 isindicative of a situation where another object/surgical instrument isapproaching and/or proximate to the surgical instrument 223100. Acontrol circuit and/or an algorithm of the surgical instrument 223100can analyze the magnitude of the measured current, the slope of themeasured current, and/or the rate of change of the slope of the measuredcurrent, for example, to provide an indication of the proximity of thesurgical instrument 223100 to another electrically conductiveobject/surgical instrument.

There are many surgical instruments which include electrical componentsin the end effector and/or shaft of the surgical instrument. In certainsurgical procedures, a surgical instrument being utilized can come intocontact with various liquids which are either from the patient orintroduced into the patient during the surgical procedure. In somecases, the liquid can come into contact with the electrical componentsin the end effector and/or shaft of the surgical instrument. When thisoccurs, the performance of the electrical components, and thus theperformance of the surgical instrument, can be affected to varyingdegrees. The degradation of the performance of the electrical componentsand/or the surgical instrument due to the exposure to the liquid isoften referred to as liquid contamination.

In some instances, when liquid contamination occurs, the electricalcomponents can still perform their primary function, but not necessarilyas well as would be possible otherwise. In other instances, one or moreof the electrical components can no longer perform their primaryfunction, which can lead to the failure of the surgical instrument. Dueto the potential performance issues associated with liquidcontamination, it is desirable to sense and detect liquid contaminationof an electrical component of a surgical instrument, and take actions toadjust for the liquid contamination.

FIG. 138 illustrates a surgical instrument 223300 including an endeffector 223302, a shaft 223304, a sensing array which includes a firstpair of sensing devices 223306A, 223306B and a second pair of sensingdevices 223308A, 223308B, and a fluid detection circuit 223310. Thesurgical instrument 223300 also includes an electrically insulativematerial 223312 and an absorption material 223314. The shaft 223304includes one or more openings 223316 through an external housing/shroud223318 of the shaft 223304 which may allow for fluid and/or othercontaminants 223320 to pass from an environment which is external to theshaft 223304 to a position within the shaft 223304.

The first pair of sensing devices 223306A, 223306B and the second pairof sensing devices 223308A, 223308B are positioned within the shaft223304 and are surrounded by the shroud 223318 of the shaft 223304. Asshown in FIG. 138, the sensing device 223306A is spaced apart from thesensing device 223306B, the sensing device 223308A is spaced apart fromthe sensing device 223308B, and the first and second pairs of sensingdevices 223306A, 223306B, 223308A, 223308B are spaced apart from oneanother. Each of the sensing devices 223306A, 223306B, 223308A, 223308Bis connected to the fluid detection circuit 223310. Based on theconfiguration of the first and second pairs of sensing devices 223306A,223306B, 223308A, 223308B, the sensing devices 223306A, 223306B,223308A, 223308B and their respective connection paths to the fluiddetection circuit 223310 may be considered a ladder circuit, where two“rungs” of the ladder are represented by the respective first and secondpairs of sensing devices 223306A, 223306B, 223308A, 223308B and the two“rails” of the ladder are represented by their respective connectionpaths to the fluid detection circuit 223310. Although only two pairs ofsensing devices are shown in FIG. 138, it will be appreciated that thesurgical instrument 223300 may include any number of pairs of sensingdevices which are spaced apart from one another and connected to thefluid detection circuit 223310 in a manner like the first and/or secondpair of sensing devices 223306A, 223306B, 223308A, 223308B, and/or anyother suitable manner.

The sensing devices 223306A, 223306B, 223308A, 223308B compriseconductivity electrodes which are electrically insulated from each otherby the electrically insulative material 223312. The electricallyinsulative material 223312 can include four or more openingscorresponding to the positions of the sensing devices 223306A, 223306B,223308A, 223308B which allow for fluid within the shaft 223304 to passtherethrough and come into contact with the sensing devices 223306A,223306B, 223308A, 223308B. When the first pair of the sensing devices223306A, 223306B are electrically isolated from one another owing to anabsence of fluid between the sensing devices 223036A and 223306B, thefluid detection circuit 223310 outputs a signal which is indicative ofthe interior volume of the shaft 223304 being dry enough for the normaloperation of the surgical instrument 223300. The signal is then passedto a control circuit (not shown) of the surgical instrument 223300,where the signal is interpreted as being indicative of a condition wherethe interior volume of the shaft 223304 is sufficiently dry as to allowfor the normal operation of the surgical instrument 223300. The controlcircuit can include a shaft processing circuit and/or a handleprocessing circuit which includes a main processor of the surgicalinstrument 223300. Alternatively, the fluid detection circuit 223310 maynot output a signal when the first pair of the sensing devices 223306A,223306B, are electrically isolated from one another, and the controlcircuit may interpret this lack of a signal as being indicative of acondition where the interior volume of the shaft 223304 is sufficientlydry as to allow for the normal operation of the surgical instrument223300.

When the fluid within the shaft 223304 is of a sufficient volume whichallows for the first pair of sensing devices 223306A, 223306B to beelectrically connected to one another via the fluid, the fluid detectioncircuit 223310 recognizes the electrical connection between the firstpair of sensing devices 223306A, 223306B and outputs a signal which isindicative of a liquid contamination condition proximate the positionsof the first pair of sensing devices 223306A, 223306B. The signal isthen passed to the control circuit. Responsive to the liquidcontamination signal, the control circuit issues one or more controlsignals which serve to adjust the operation of the surgical instrument223300. For example, the control circuit can issue one or more controlsignals which serve to lower the amount of power available to thesurgical instrument 223300, lock out or disable one or more functions ofthe surgical instrument 223300, and/or lock out or disable one or moreelectrical traces which are susceptible to signal loss orshort-circuiting, for example. Also, for example, the fluid detectioncircuit 223310 may not output a signal when the sensing devices 223306A,223306B are electrically connected to one another via the fluid, and thecontrol circuit may interpret this lack of a signal as being indicativeof a liquid contamination condition. The electrical connection betweenthe sensing devices 223306A, 223306B provides an indication whether ornot the fluid has intruded a first distance into the surgical instrument223300, where the first distance corresponds to the positions of thesensing devices 223306A, 223306B within the shaft 223304.

When the second pair of the sensing devices 223308A, 223308B areelectrically isolated from one another, the fluid detection circuit223310 can output a signal which is indicative of the interior volume ofthe shaft 223304 being dry enough for continued operation of thesurgical instrument 223300. The signal is then passed to the controlcircuit of the surgical instrument 223300, where the signal isinterpreted as being indicative of a condition where the interior volumeof the shaft 223304 proximate the positions of the sensing devices223308A, 223308B is sufficiently dry as to allow for the continuedoperation of the surgical instrument 223300. Alternatively, the fluiddetection circuit 223310 may not output a signal when the second pair ofthe sensing devices 223308A, 223308B, are electrically isolated from oneanother, and the control circuit may interpret this lack of a signal asbeing indicative of a condition where the interior volume of the shaft223304 is sufficiently dry as to allow for the continued operation ofthe surgical instrument 223300.

When the fluid within the shaft 223304 is of a sufficient volume whichallows for the second pair of sensing devices 2233086A, 223308B to beelectrically connected to one another via the fluid, the fluid detectioncircuit 223310 recognizes the electrical connection between the secondpair of sensing devices 223308A, 223308B and outputs a signal which isindicative of a liquid contamination condition proximate to thepositions of the sensing devices 2233086A, 223308B. The signal is thenpassed to the control circuit. Responsive to the liquid contaminationsignal, the control circuit issues one or more control signals whichserve to adjust the operation of the surgical instrument 223300. Forexample, the control circuit can issue one or more control signals whichserve to lower the amount of power available to the surgical instrument223300, lock out or disable one or more functions the surgicalinstrument 223300, and/or lock out or disable one or more electricaltraces which are susceptible to signal loss or short-circuiting, forexample. Alternatively, the fluid detection circuit 223310 may notoutput a signal when the sensing devices 223308A, 223308B areelectrically connected to one another via the fluid, and the controlcircuit may interpret this lack of a signal as being indicative of aliquid contamination condition. The electrical connection between thesensing devices 223308A, 223308B provides an indication whether or notthe fluid has further intruded to a second distance into the surgicalinstrument 223300, where the second distance corresponds to thepositions of the sensing devices 223308A, 223308B within the shaft223304.

In various instances, the sensing devices 223306A, 223306B, 223308A,223308B, the electrically insulative material 223312, and/or the fluiddetection circuit 223310 can form portions of a flex circuit 223322which is positioned within the shaft 223004 and can conform to theinterior surface of the external housing or shroud 223318 of the shaft223004. That said, the sensing devices 223306A, 223306B, 223308A,223308B, the electrically insulative material 223312, and/or the fluiddetection circuit 223310 can be arranged in any suitable manner.

The absorption material 223314 is configured to absorb the fluid withinthe shaft 223004. By absorbing the fluid, the absorption material 223314slows the ingress of the fluid into the surgical instrument 223300;however, the fluid will ultimately wick through the absorption material223314 toward the second pair of sensing devices 223308A, 223308B.Notably, the first pair of sensing devices 223306A, 223306B arepositioned distally with respect to the absorption material 223314 and,as a result, any initial fluid intrusion will quickly reach the firstpair of sensing devices 223306A, 223306B. On the other hand, at least aportion of the absorption material 223314 is present between the firstpair of sensing devices 223306A, 223306B and the second pair of sensingdevices 223308A, 223308B and, as a result, the fluid intrusion may ormay not reach the second pair of sensing devices 223308A, 223308B. As aresult, the fluid detection circuit 223310 is configured to use theelectrical connection between the first pair of sensing devices 223306A,223306B as a fluid intrusion/contamination warning which does notnecessarily change any operation of the surgical instrument 223300, andto use the electrical connection between the second pair of sensingdevices 223308A, 223308B as a fluid intrusion/contamination warningwhich does change the operation of the surgical instrument 223300.

As shown in FIG. 138, the absorption material 223314 may be configuredin the form of a ring or cylinder which is concentric with the externalhousing/shroud 223318 of the shaft 223004. The second pair of sensingdevices 223308A, 223308B are positioned between the absorption material223314 and the external housing/shroud 223318 which further limits andcontrols the potential ingress of the fluid into the surgical instrument223300.

In various instances, the above-described sensing array and/or anothersimilar sensing array can be used in concert with the absorptionmaterial 223314 to not only detect the presence of fluid within theshaft 223304, but also to detect when the fluid has reached an amountwhich can no longer be adequately handled by various electricalcomponents of the surgical instrument 223300. Stated differently, thiscombination can help determine how much fluid is in the shaft 223304. Itwill be appreciated that some electrical components of the surgicalinstrument 223300 can perform their primary function better than otherelectrical components of the surgical instrument 223300 can when bothare exposed to the same volume of fluid. Similarly, some electricalcomponents of the surgical instrument 223300 will fail before otherelectrical components of the surgical instrument 223300 will fail whenboth are exposed to the same volume of fluid.

FIG. 139 illustrates an electrical circuit 223400 of the surgicalinstrument 223300 of FIG. 138. The electrical circuit 223400, or atleast a portion of the electrical circuit 223400, can be positionedwithin the absorption material 223314 of the surgical instrument 223300and can be utilized to determine when fluid in the shaft 223004 hasreached a volume which can no longer be adequately handled by one ormore electrical components of the surgical instrument 223300. Theelectrical circuit 223400 includes a sensing array which includes afirst pair of sensing devices 223402A, 223402B and a second pair ofsensing devices 223404A, 223404B. The first and second pairs of sensingdevices 223402A, 223402B, 223404A, 223404B can be the first and secondpairs of sensing devices 223306A, 223306B, 223308A, 223308B shown inFIG. 138, respectively, or additional sensing devices. Thus, it shouldbe appreciated that the electrical circuit 223400 can form a part of theflexible circuit 223322 and can also be electrically connected to thefluid detection circuit 223310.

The electrical circuit 223400 also includes a first comparator 223406which is electrically connected to the first pair of sensing devices223402A, 223402B, and a second comparator 223408 which is electricallyconnected to the second pair of sensing devices 223404A, 223404B. Asexplained in greater detail below, the first and second comparators223406, 223408 are utilized to determine whether an input has reachedsome predetermined value. In various instances, the first and secondcomparators 223406, 223408 are realized with operational amplifiers. Incertain instances, the first and second comparators 223406, 223408 arerealized with a dedicated comparator integrated circuit. The electricalcircuit 223400 further includes a first resistive element 223410 whichis electrically connected to the first pair of sensing devices 223402A,223402B, and a second resistive element 223412 which is electricallyconnected to the second pair of sensing devices 223404A, 223404B.

Based on the configuration of the first and second pairs of sensingdevices 223402A, 223402B, 223404A, 223404B and their respectiveconnection paths back to the power source V, at least part of theelectrical circuit 223400 may be considered a ladder circuit, where tworungs of the ladder are represented by the respective first and secondpairs of sensing devices 223402A, 223402B, 223404A, 223404B and the tworails of the ladder are represented by their respective connection pathsback to the power source V. Although only two pair of sensing devicesare shown in FIG. 139, it should be appreciated that the electricalcircuit 223400 may include any number of pairs of sensing devices, whichare spaced apart from one another and connected to the power source V ina manner like the first and/or second pair of sensing devices 223402A,223402B, 223404A, 223404B, as well as any number of correspondingcomparators.

In operation, when a sufficient amount of fluid within the shaft 223004causes the first pair of sensing devices 223402A, 223402B to beelectrically connected to one another via the fluid, the first pair ofsensing devices 223402A, 223402B provide a voltage signal to a firstinput (e.g., the negative − input) of the first comparator 223406. Thefirst comparator 223406 then compares the voltage signal from the firstpair of sensing devices 223402A, 223402B with a reference voltage whichis connected to a second input (e.g., the positive + input) of the firstcomparator 223406. Based on which voltage is larger, the firstcomparator 223406 then outputs either a “high” signal or a “low” signal.For example, when the reference voltage is greater than the voltagesignal from the first pair of sensing devices 223402A, 223402B, thefirst comparator 223406 outputs a “low” signal which is an indicationthat the volume of fluid within the shaft 223004 proximate to the firstpair of sensing devices 223402A, 223402B has not yet reached a levelthat cannot be adequately handled by the electrical components of thesurgical instrument 223300. This would also be the case when the sensingdevices 223402A, 223402B are electrically isolated from one another. Onthe other hand, when the voltage signal from the first pair of sensingdevices 223402A, 223402B, is greater than the reference voltage, thefirst comparator 223406 outputs a “high” signal which is an indicationthat the amount of fluid proximate to the first pair of sensing devices223402A, 223402B has reached a level within the shaft 223304 which canno longer be adequately handled by one or more electrical components ofthe surgical instrument 223300. In either case, the signal output by thefirst comparator 223406 may be passed to the control circuit of thesurgical instrument 223300 for further action.

Similarly, when the absorption material 223314 has absorbed a sufficientamount of fluid from within the shaft 223004 to cause the second pair ofsensing devices 223404A, 223404B to be electrically connected to oneanother via the absorbed fluid, the second pair of sensing devices223404A, 223404B provide a voltage signal to a first input (e.g., thenegative − input) of the second comparator 223408. The first comparator223408 then compares the voltage signal from the second pair of sensingdevices 223404A, 223404B with a reference voltage which is connected toa second input (e.g., the positive+input) of the second comparator223408. Based on which voltage is larger, the second comparator 223408then outputs either a “high” signal or a “low” signal. For example, whenthe reference voltage is greater than the voltage signal from the secondpair of sensing devices 223404A, 223404B, the second comparator 223408outputs a “low” signal which is an indication that the volume of fluidwithin the shaft 223004 has not yet reached a level that cannot beadequately handled by the electrical components of the surgicalinstrument 223300. This would also be the case when the sensing devices223404A, 223404B are electrically isolated from one another. On theother hand, when the voltage signal from the second pair of sensingdevices 223404A, 223404B, is greater than the reference voltage, thesecond comparator 223408 outputs a “high” signal which is an indicationthat the amount of fluid absorbed by the absorption material 223314 hasreached a saturation level, which is an indication that the volume offluid within the shaft 223004 can no longer be adequately handled by oneor more electrical components of the surgical instrument 223300. Ineither case, the signal output by the second comparator 223408 may bepassed to the control circuit of the surgical instrument 223300 forfurther action.

Responsive to a “high” output signal from the first comparator 223406and/or the second comparator 223408, the control circuit can issue oneor more control signals which serve to issue a signal degradationwarning, issue a component and/or sub-system failure warning, lower theamount of power available to the surgical instrument 223300, lock out ordisable one or more functional features of the surgical instrument223300, and/or lock out or disable one or more electrical traces whichare susceptible to signal loss or short-circuiting, for example.

Although the same reference voltage is shown in FIG. 139 as beingapplied to the first comparator 223406 as well as to the secondcomparator 223408, it will be appreciated that a first reference voltagecan be applied to the first comparator 223406 and a second referencevoltage can be applied to the second comparator 223408, where the firstand second voltage references are different from one another. Forexample, if the first reference voltage is lower than the secondreference voltage, the output signal from the first comparator 223406can provide an indication that a “level 1” fluid contamination level hasbeen reached in the shaft 223004 where electrical signals are degradedand/or the performance of at least one electrical component of thesurgical instrument 223000 is in danger of being affected, and theoutput signal from the second comparator 223408 can provide anindication that a “level 2” fluid contamination level has been reachedin the shaft 223004 where electrical signals are even further degradedand/or the performance of at least one other electrical component of thesurgical instrument 223000 is in danger of being affected. Based on thedifferent meanings of the output signals passed to the control circuitof the surgical instrument 223300, the control circuit can issue controlsignals which serve to adjust the operations of the surgical instrument223300 differently and/or adjust different operations of the surgicalinstrument 223000. For example, when a “level 1” fluid contaminationlevel signal is output from the first comparator 223406, the controlcircuit issues one or more control signals which serve to lower theamount of power available to the surgical instrument 223300. When a“level 2” fluid contamination level signal is output from the secondcomparator 223408, the control circuit issues one or more controlsignals which serve to further lower the amount of power available tothe surgical instrument 223300, lock out or disable one or morefunctional features of the surgical instrument 223300, and/or lock outor disable one or more electrical traces which are susceptible to signalloss or short-circuiting, for example.

Furthermore, although the sensing devices 223402A, 223402B, 223404A,223404B are shown in FIG. 139 as being in an “open” position (e.g., notelectrically connected to one another), the above-describedfunctionality of the electrical circuit 223400 can also be realized withthe sensing devices 223402A, 223402B, 223404A, 223404B being in a“closed” position. As long as the sensing devices 223402A, 223402B,223404A, 223404B remain in the “closed” position and pass respectivevoltage signals to the first and second comparators 223406, 223408, theoutput signals of the first comparator 223406 and/or the secondcomparator 223408 would be an indication that the volume of fluid withinthe shaft 223004 has not yet reached a level that cannot be adequatelyhandled by the electrical components of the surgical instrument 223300.As more and more fluid comes into the shaft 223004 and is absorbed bythe absorption material 223314, the absorption material 223314 furtherexpands, eventually reaching the point where the electrical connectionbetween the second pair of sensing devices sensing 223404A, 223404B isbroken/pulled apart, thereby breaking/altering the electricalcontinuity/conductivity within the electrical circuit 223400. Thebreaking/altering in the continuity/conductivity changes the respectivevoltage signals applied to the first inputs (e.g., the negative −inputs) of the first and second comparators 223406, 223408, which inturn changes the meaning of the signals output by the first and secondcomparators 223406, 223408.

When a surgical instrument is used during a surgical procedure, thedensity of the air associated with the environment in which the surgicalprocedure is taking place can have an effect on the performance of thesurgical instrument. In most case, the altitude the surgical procedureis taking place at can be a proxy for the air density. For example, asurgical instrument being used in a high altitude location where the airis generally less dense than at sea level can perform differently thanwhen the surgical instrument is used at or near sea level. Due toperformance issues associated with air density/altitude, it is desirableto sense/detect the air density/altitude which the surgical instrumentis operating at, and adjust various thresholds, control parametersand/or sensed values to compensate for differences in altitude.

Heat dissipation within a surgical instrument is one performancecharacteristic which changes with altitude. As the altitude increases,there is less air for a given volume and, as a result, the atmosphericpressure decreases. As the atmospheric pressure decreases, air moleculesspread out further and the temperature decreases. There are certainparts of a surgical instrument which rely on convection cooling todissipate heat generated by the operation of the surgical instrument.With convection cooling, the heat generated by the operation of thesurgical instrument is transferred from the surgical instrument to theair surrounding the surgical instrument. At higher altitudes, where theatmospheric pressure is lower and there is less air (the air density islower), the convection cooling is less efficient due to there being lessair, and it is more difficult to dissipate the waste heat generated bythe electronics of the surgical instrument which drive motors, generatehigh frequency electrosurgical energy for radio-frequency (RF), and/orultrasonic type applications, for example, due to the convection coolingbeing less efficient. This is why motor heat dissipation efficiencydecreases with increasing altitudes.

Air volume delivered by a compressor pump in a smoke evacuation systemutilized with a surgical procedure is another performance characteristicwhich changes with altitude. The compressor pump will deliver the samevolume of air regardless of the weight or density of the air (asaltitude increases, the weight and density of the air becomes lower andlower). However, since the weight of the air is lower at higheraltitudes, the compressor pump requires less electrical power to deliverthe same volume of air at higher altitudes. Stated differently, todeliver a given volume of air at a higher altitude, the motor speed ofthe compressor pump can be decreased. That said, to deliver a givenweight of air at a higher altitude, the motor speed of the compressorpump is increased.

In view of the above, it will be appreciated why it is desirable tosense/detect the altitude (as a proxy for the air density) which thesurgical instrument is operating at, and adjust various thresholds,control parameters and/or sensed values to compensate for differences inaltitude. The altitude can be sensed/detected in a number of differentways. For example, the surgical instrument can include a sensing devicewhich senses and measures atmospheric/barometric pressure, such as abarometric pressure sensor, for example. The sensed atmospheric pressureis a proxy for the altitude. Based on the sensed atmospheric pressure, acontrol circuit and/or algorithm of the surgical instrument can issueone or more control signals which operate to alter/adjust the normaloperation of the surgical instrument to account for the altitude/airdensity. In addition to or in lieu of taking direct readings of theatmospheric pressure, the surgical instrument can include a globalpositioning system (GPS) receiver which determines the precise positionof the receiver. In such instances, the control circuit and/or algorithmcan correlate the GPS readings with a GPS location, the known altitudeand average atmospheric barometric readings at the GPS location, andissue one or more control signals to alter/adjust the normal operationof the surgical instrument to account for the altitude/air density atthat location. There are also several ways to estimate/calculate ade-rating factor which can be applied to the various thresholds, controlparameters and/or sensed values to account for changes in altitude/airdensity.

FIG. 140 illustrates a graph 223500 which shows relationships betweenaltitude, atmospheric pressure 223502 and electrical power 223504utilized by a surgical instrument, in various instances. The graph223500 can be utilized to determine de-rating factors corresponding todifferent sensed/detected altitudes, where the altitudes are proxies fordifferent air densities. The altitude is shown along a first horizontalaxis 223506 as elevation from sea level. A second horizontal axis 223508is aligned with the first horizontal axis 223506 and also represents theelevation from sea level. A power percentage is shown along a firstvertical axis 223510 and a scaled atmospheric pressure is shown along asecond vertical axis 223512. As shown in FIG. 140, as the elevationincreases, the atmospheric pressure 223502 decreases and the electricalpower 223504 utilized by the surgical instrument decreases. At sea level(elevation=0), the atmospheric pressure 223502 is at the scaled level of1, and the electrical power 223504 is at 100% power (full power). At anelevation of 10,000 feet above sea level, the atmospheric pressure223502 is at the scaled level of approximately 0.20, and the electricalpower 223504 is at 70% power (30% less than full power). Stateddifferently, at an atmospheric pressure 223502 associated with anelevation of 10,000 feet above sea level, temperature thresholdsassociated with the surgical instrument can be de-rated by 30%. Similarde-rating percentages can be determined for other elevations by simplydetermining where a vertical line aligned with a given elevation on thefirst horizontal axis 223506 crosses the electrical power 223504 and theatmospheric pressure 223502. In various instances, the de-ratingpercentages can be stored as a look-up table in a memory device of acontrol circuit of the surgical instrument, and can be utilized by thecontrol circuit and/or an algorithm to apply de-rating factors to thevarious thresholds, control parameters and/or sensed values to accountfor the sensed/detected air densities.

Another method for determining de-rating factors and/or other applicableadjustments for differences in altitude can be found, for example, in awhite paper entitled A METHOD FOR APPROXIMATING COMPONENT TEMPERATURESAT ALTITUDE CONDITIONS BASED ON CFD ANALYSIS AT SEA LEVEL CONDITIONSauthored by Bruno Zoccali, the disclosure of which is herebyincorporated by reference in its entirety. The white paper was publiclyavailable on the website of TDMG Inc. (www.tdmginc.com) as of Dec. 6,2018.

The surgical instruments disclosed herein are configured to includetemperature sensors positioned within a handle assembly and/or a shaftof the surgical instrument. The surgical instrument can be any of thesurgical instruments described herein. The temperature sensors arepositioned to sense the temperature of certain components and/orsub-systems positioned within the handle assembly and/or the shaft ofthe surgical instrument. For example, the temperature sensors may bepositioned to sense the temperature of an electric motor, powercircuitry, and/or communication circuitry, for example. The sensedtemperatures may be utilized by a control circuit of the surgicalinstrument, such as a main processor in a handle assembly of thesurgical instrument, for example, and/or an algorithm to adjust/adaptthe operation of the surgical instrument.

In various instances, thermal sensing devices can be built into flexcircuits within different parts of the surgical instrument, and thetemperatures measured/sensed by the thermal sensing devices can beutilized by the control circuit and/or an algorithm to determine if atemperature of a given component and/or sub-system is in a warning ordanger zone. Once the sensed/measured temperature of a given componentand/or sub-system is determined to be above the warning level, thecontrol circuit and/or the algorithm can further operate to beginreducing the level of power supplied to the highest heat creatingcomponents and/or systems. For example, the level of power supplied tothe drive motor of the surgical instrument can be reduced.

Once the sensed/measured temperature of a given component and/orsub-system is determined to be over a predetermined critical threshold,the control circuit and/or the algorithm can act to place the surgicalinstrument into a shut down condition, where the electronics of thesurgical instrument which function to provide communication with asurgical hub stay energized but the surgical instrument is otherwiseprevented from performing certain functionalities, such as closing jaws,firing staples, and/or delivering high frequency electrosurgical energy,for example. By keeping the electronics which function to providecommunication with the surgical hub energized, the surgical hub cancontinue to keep a user of the surgical instrument informed regardingthe operational status of the surgical instrument. Various aspects of asurgical hub are described in more detail in U.S. patent applicationSer. No. 15/940,629, entitled COMPUTER IMPLEMENTED INTERACTIVE SURGICALSYSTEMS, filed on Mar. 29, 2018, the disclosure of which is herebyincorporated by reference in its entirety.

In order to manage the temperatures of the components and/or sub-systemsof the surgical instrument and the continued operation of the surgicalinstrument in heavy use conditions, in various instances, the priorityof operation can be based on the importance level of the component,subsystem and/or task to be performed. Therefore, in certaincircumstances the surgical instrument can be controlled such that thehighest heat generator can go unregulated or only be regulated after acritical task is accomplished.

In some instances, when a component and/or subsystem of the surgicalinstrument is being regulated, a control circuit of the surgicalinstrument, such as a main processor in a handle assembly of thesurgical instrument, for example, can communicate with the surgical hubin order to receive more information on how best to proceed. In someinstances, the situational awareness functionality of the surgical hubcan operate to inform the control circuit of the surgical instrumentthat the surgical instrument is in the middle of a critical task, andthe control circuit and/or an algorithm can then control the surgicalinstrument to either ignore the heat warning or reprioritize theimportance of the component and/or sub-system that was being regulated.Various aspects of situational awareness functionality are described,for example, in U.S. patent application Ser. No. 15/940,654, entitledSURGICAL HUB SITUATIONAL AWARENESS, filed on Mar. 29, 2018, thedisclosure of which is herein incorporated by reference in its entirety.

In some instances, the surgical instrument can be controlled toproportionally limit motor power use based on the sensed/measuredtemperatures or on estimated temperatures. For example, as predeterminedtemperature thresholds are exceeded and/or the rate of temperature riseexceeds a predetermined threshold and/or a modeled heat build-up isapproaching a predetermined threshold, the surgical instrument can becontrolled to reduce the level of power made available to the motor as afirst priority, then reduce the power available for the energy modality(e.g., electrosurgical energy, ultrasonic energy), if any.

FIG. 141 illustrates a method 223600 for determining heat flux fromsensed/measured temperatures over time to predict an occurrence of apredefined temperature threshold being exceeded. At step 223602, thetemperatures of the components and/or sub-systems positioned within thehandle assembly and/or the shaft of the surgical instrument aresensed/measured by a temperature sensing device. At step 223604, theenergy delivered to each motor and to the power circuitry of thesurgical instrument is measured over time by an energy measuring device.At step 223606, the accumulated heat built-up inside the surgicalinstrument is estimated based on the information determined at steps223602 and 223604. At step 223608, the rate of the temperature risewithin the surgical instrument is determined by a control circuit and/oralgorithm of the surgical instrument. Based on the determined rate ofthe temperature rise at step 223608, the time at which the predefinedtemperature threshold will be exceeded can be determined at step 223610by the control circuit and/or an algorithm of the surgical instrument.In some instances, the method 223600 further comprises a step 223612,wherein the rate of temperature rise determined at step 223608 can becompared to a rate of temperature rise predicted by a modeled heatbuild-up to establish a higher level of confidence of the accuracy ofthe determined rate of temperature rise. This comparison can beperformed by the control circuit of the surgical instrument.

FIG. 142 illustrates a graph 223700 which shows a relationship between asensed temperature 223702, an approximated temperature 223704, and anenergy usage 223706 of the surgical instrument. The time t is shownalong a first horizontal axis 223708 and along a third horizontal axis223712. A second horizontal axis 223710 also represents time t. A firstvertical axis 223714 is associated with the approximated temperature223704, a second vertical axis 223716 is associated with the sensedtemperature 223702, and a third vertical axis 223718 is associated withthe energy usage 223706. In various instances, the sensed temperature223702 is a temperature sensed within a handle assembly of the surgicalinstrument, the approximated temperature is a temperature which isestimated by a heat build-up model, and the energy usage 223706represents the total of all energy consumed by the surgical instrumentduring its use in a surgical procedure.

As shown in FIG. 142, when the surgical instrument is first energized,the level of energy 223706 used by the surgical instrument is very low.The small increase in the sensed temperature 223702 can be attributed tothe electrical circuits within the surgical instrument being energized.From time t₁ to time t₂, when an end effector of the surgical instrumentis being articulated, the energy usage 223706 increases and the sensedtemperature 223702 increases. The approximated temperature 223704 isshown increasing at time t₂. As the articulation is paused between timet₂ and time t₃, the energy usage 223706 stays the same, the sensedtemperature 223702 continues to increase, and the approximatedtemperature 223704 stays the same. From time t₃ to time t₄, when the endeffector is further articulated, the energy usage 223706 increases andthe sensed temperature 223702 increases. The approximated temperature223704 is shown increasing at time t₄.

As the articulation is paused again between time t₄ and time t₅, theenergy usage 223706 stays the same, the sensed temperature 223702continues to increase and the approximated temperature 223704 stays thesame. At time t₅, the energy modality of the surgical instrument, suchas the application of mechanical energy, electrosurgical energy, and/orultrasonic energy, for example, is energized, the energy usage 223706begins to increase significantly, the sensed temperature 223702 reachesthe motor temperature threshold 223720 (which is the same for the sensedtemperature 223702 and the approximated temperature 223704), and theapproximated temperature 223704 increases and passes the motor threshold223720 in the process.

From time t₅ to time t₆, as the energy modality continues to beenergized, the energy usage 223706 increases significantly, the sensedtemperature 223702 increases significantly, exceeding the motorthreshold 223720 at approximately time t₅ and reaching the energythreshold 223722 at time t₆. As a result of the sensed temperature223702 exceeding the motor threshold 223720 at approximately time t₅, acontrol circuit and/or an algorithm of the surgical instrument, such asa main processor in a handle assembly of the surgical instrument, forexample, and/or an algorithm acts to limit the power delivered to themotor (or motors) of the surgical instrument. This limiting remains ineffect until the sensed temperature 223702 falls back below the motorthreshold 223720 at approximately time t₁₀.

At approximately time t₆, the sensed temperature 223702 passes theenergy threshold 223722. As a result of the sensed temperature 223702exceeding the energy threshold 223722 at approximately time t₆, thecontrol circuit and/or the algorithm acts to limit the power deliveredto the energy modality of the surgical instrument. This limiting remainsin effect until the sensed temperature 223702 falls back below theenergy threshold 223722 at approximately time t₇. Once the limiting ofthe power delivered to the energy modality 223702 is halted at time t₇,the sensed temperature 223702 begins to decrease. From time t₈ to timet₉, although the sensed temperature 223702 is still above the motorthreshold 223720, the control circuit and/or the algorithm may allow theend effector to be articulated once again because the sensed temperature223702 is decreasing.

According to various aspects, the motor threshold 223720 and the energythreshold 223722 can be altered/adjusted by the control circuit and/oran algorithm to compensate for differences in air density, altitudeand/or atmospheric pressure as described above.

The devices, systems, and methods disclosed in the Subject applicationcan be used with the devices, systems, and methods disclosed in U.S.patent application Ser. No. 13/832,786, now U.S. Pat. No. 9,398,905,entitled CIRCULAR NEEDLE APPLIER WITH OFFSET NEEDLE AND CARRIER TRACKS;U.S. patent application Ser. No. 14/721,244, now U.S. Pat. No.10,022,120, entitled SURGICAL NEEDLE WITH RECESSED FEATURES; and U.S.patent application Ser. No. 14/740,724, now U.S. Pat. No. 9,888,914,entitled SUTURING INSTRUMENT WITH MOTORIZED NEEDLE DRIVE, which areincorporated by reference in their entireties herein.

The devices, systems, and methods disclosed in the Subject applicationcan be used with the devices, systems, and methods disclosed in U.S.Provisional Patent Application Ser. No. 62/659,900, entitled METHOD OFHUB COMMUNICATION, filed on Apr. 19, 2018, U.S. Provisional PatentApplication Ser. No. 62/611,341, entitled INTERACTIVE SURGICAL PLATFORM,filed on Dec. 28, 2017, U.S. Provisional Patent Application Ser. No.62/611,340, entitled CLOUD-BASED MEDICAL ANALYTICS, filed on Dec. 28,2017, and U.S. Provisional Patent Application Ser. No. 62/611,339,entitled ROBOT ASSISTED SURGICAL PLATFORM, filed on Dec. 28, 2017, whichare incorporated by reference in their entireties herein. The devices,systems, and methods disclosed in the Subject application can also beused with the devices, systems, and methods disclosed in U.S. patentapplication Ser. No. 15/908,021, entitled SURGICAL INSTRUMENT WITHREMOTE RELEASE, filed on Feb. 28, 2018, U.S. patent application Ser. No.15/908,012, entitled SURGICAL INSTRUMENT HAVING DUAL ROTATABLE MEMBERSTO EFFECT DIFFERENT TYPES OF END EFFECTOR MOVEMENT, filed on Feb. 28,2018, U.S. patent application Ser. No. 15/908,040, entitled SURGICALINSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING MULTIPLE END EFFECTORFUNCTIONS, filed on Feb. 28, 2018, U.S. patent application Ser. No.15/908,057, entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELYACTUATING MULTIPLE END EFFECTOR FUNCTIONS, filed on Feb. 28, 2018, U.S.patent application Ser. No. 15/908,058, entitled SURGICAL INSTRUMENTWITH MODULAR POWER SOURCES, filed on Feb. 28, 2018, and U.S. patentapplication Ser. No. 15/908,143, entitled SURGICAL INSTRUMENT WITHSENSOR AND/OR CONTROL SYSTEMS, filed on Feb. 28, 2018, which areincorporated by reference in their entireties herein. The devices,systems, and methods disclosed in the Subject application can also beused with the devices, systems, and methods disclosed in U.S. patentapplication Ser. No. 14/226,133, now U.S. Patent Application PublicationNo. 2015/0272557, entitled MODULAR SURGICAL INSTRUMENT SYSTEM, filed onMar. 26, 2014, which is incorporated by reference in its entiretyherein.

Various aspects of the subject matter described herein are set out inthe following example sets.

Example Set 1 Example 1

A method for controlling a surgical instrument. The method comprisingoperating a drive system driven by an electric motor and a motor controlcircuit, sensing strain within the surgical instrument via a strain gagecircuit in communication with the motor control circuit, and changingthe speed of the electric motor via the motor control circuit based oninput from the strain gage circuit.

Example 2

The method of Example 1, wherein the changing step comprises slowing thespeed of the electric motor when the strain measured by the strain gagecircuit exceeds a threshold limit.

Example 3

The method of Example 2, wherein the changing step comprises increasingthe speed of the electric motor if the strain measured by the straingage circuit returns below the threshold limit.

Example 4

The method of Example 1, wherein the surgical instrument comprises ashaft and an end effector rotatably connected to the shaft, and whereinthe operating step comprises rotating the end effector relative to theshaft.

Example 5

The method of Examples 1, 2, or 3, wherein the surgical instrumentcomprises an end effector including a movable jaw, and wherein theoperating step comprises moving the jaw.

Example 6

The method of Examples 1, 2, 3, 4, or 5, wherein the surgical instrumentcomprises a firing system including a movable firing member, and whereinthe operating step comprises moving the firing member.

Example 7

The method of Examples 1, 2, 3, 4, 5, or 6, wherein the surgicalinstrument comprises a shroud, and wherein the strain gage circuitcomprises a strain gage attached to the shroud.

Example 8

The method of Examples 1, 2, 3, 4, 5, or 6, wherein the surgicalinstrument comprises a shroud, and wherein the strain gage circuitcomprises a strain gage attached to the shroud.

Example 9

The method of Examples 1, 2, 3, 4, 5, or 6, wherein the surgicalinstrument comprises a shroud, and wherein the strain gage circuitcomprises a strain gage embedded in the shroud.

Example 10

The method of Examples 1, 2, 3, 4, 5, 6, 7, 8, or 9, wherein thesurgical instrument comprises a handle including a handle housing,wherein the strain gage circuit comprises a strain gage attached to thehandle housing, and wherein the method further comprises pressing thehandle housing to control the speed of the electric motor.

Example 11

The method of Examples 1, 2, 3, 4, 5, 6, 7, 8, or 9, wherein thesurgical instrument comprises a handle including a handle housing,wherein the strain gage circuit comprises a strain gage embedded in thehandle housing, and wherein the method further comprises pressing thehandle housing to control the speed of the electric motor.

Example 12

The method of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11, wherein thedrive system comprises a drive shaft, and wherein at least a portion ofthe strain gage circuit is mounted to the drive shaft.

Example 13

The method of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, whereinthe motor control circuit comprises default operating controls, whereinthe strain gage circuit provides data to the motor control circuit, andwherein the motor control circuit modifies the default operatingcontrols based on the data from the strain gage circuit.

Example 14

A method for controlling a surgical instrument. The method comprisingoperating a drive system driven by an electric motor and a motor controlsystem, sensing strain within the surgical instrument via a strain gagecircuit in communication with the motor control system, and changing thespeed of the electric motor via the motor control system based on datafrom the strain gage circuit.

Example 15

The method of Example 14, wherein the motor control system comprisesdefault operating controls, and wherein the motor control systemmodifies the default operating controls based on the data from thestrain gage circuit.

Example 16

The method of Examples 14 or 15, wherein the surgical instrumentcomprises a handle including a handle housing, wherein the strain gagecircuit comprises a strain gage attached to the handle housing, andwherein the method further comprises pressing the handle housing tocontrol the speed of the electric motor.

Example 17

The method of Examples 14 or 15, wherein the surgical instrumentcomprises a handle including a handle housing, wherein the strain gagecircuit comprises a strain gage embedded in the handle housing, andwherein the method further comprises pressing the handle housing tocontrol the speed of the electric motor.

Example 18

A method for controlling a surgical instrument. The method comprisingoperating the surgical instrument using a control system, wherein thesurgical instrument comprises a shroud, sensing a parameter of theshroud using a sensor circuit in communication with the control system,and modifying the operation of the surgical instrument based on datafrom the sensor circuit.

Example 19

The method of Example 18, wherein the control system comprises defaultoperating controls, and wherein the control system modifies the defaultoperating controls based on the data from the sensor circuit.

Example Set 2 Example 1

A surgical instrument comprising a handle, a shaft extending from thehandle, an end effector extending from the shaft, a drive electricmotor, and a shifter electric motor configurable in a firstconfiguration, a second configuration, and a third configuration. Thesurgical instrument further comprises a first drive system configured toperform a first end effector function. The first drive system isdrivable by the drive electric motor when the shifter electric motor isin the first configuration. The surgical instrument further comprises asecond drive system configured to perform a second end effectorfunction. The second drive system is drivable by the drive electricmotor when the shifter electric motor is in the second configuration.The surgical instrument further comprises a third drive systemconfigured to perform a third end effector function. The third drivesystem is drivable by the drive electric motor when the shifter electricmotor is in the third configuration. The second drive system and thethird drive system are not drivable by the drive electric motor when theshifter electric motor is in the first configuration. The first drivesystem and the third drive system are not drivable by the drive electricmotor when the shifter electric motor is in the second configuration.The first drive system and the second drive system are not drivable bythe drive electric motor when the shifter electric motor is in the thirdconfiguration.

Example 2

The surgical instrument of Example 1, wherein the shifter electric motorcomprises a solenoid.

Example 3

The surgical instrument of Examples 1 or 2, wherein the drive electricmotor comprises a rotatable drive output shaft and a drive output gearmounted to the drive output shaft, wherein the shifter electric motorcomprises a translatable shifter shaft and a rotatable shifter gear,wherein the shifter gear is operably engaged with the drive output gearand selectively engageable with the first drive system, the second drivesystem, and the third drive system.

Example 4

The surgical instrument of Examples 1, 2, or 3, wherein the first drivesystem comprises a first rotatable drive shaft, wherein the second drivesystem comprises a second rotatable drive shaft, wherein the third drivesystem comprises a third rotatable drive shaft, and wherein the firstrotatable drive shaft, the second rotatable drive shaft, and the thirdrotatable drive shaft are nested along a longitudinal axis.

Example 5

The surgical instrument of Examples 1, 2, 3, or 4, further comprising anarticulation joint rotatably connecting the end effector to the shaft,wherein the end effector comprises a clampable jaw and a translatablefiring member, wherein the first end effector function comprisesarticulating the end effector relative to the shaft, wherein the secondend effector function comprises moving the jaw into a clamped position,and wherein the third end effector function comprises moving the firingmember through a firing stroke.

Example 6

The surgical instrument of Example 5, further comprising a staplecartridge including staples removably stored therein, wherein the firingmember is configured to deploy the staples from the staple cartridgeduring the firing stroke.

Example 7

The surgical instrument of Examples 5 or 6, further comprising a seconddrive motor configured to drive a fourth drive system to perform thesecond end effector function.

Example 8

The surgical instrument of Examples 1, 2, 3, or 4, further comprising asecond drive motor configured to drive a fourth drive system to performthe second end effector function.

Example 9

The surgical instrument of Examples 7 or 8, wherein the drive electricmotor and the second drive motor are operable at the same time.

Example 10

The surgical instrument of Examples 7, 8, or 9, wherein the driveelectric motor and the second drive motor are operable at differenttimes.

Example 11

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10,further comprising a staple cartridge.

Example 12

A surgical system comprising a housing, a shaft extending from thehousing, an end effector extending from the shaft, a drive electricmotor, and a shifter electric motor configurable in a firstconfiguration, a second configuration, and a third configuration. Thesurgical system further comprises a first drive system configured toperform a first end effector function. The first drive system isdrivable by the drive electric motor when the shifter electric motor isin the first configuration. The surgical system further comprises asecond drive system configured to perform a second end effectorfunction. The second drive system is drivable by the drive electricmotor when the shifter electric motor is in the second configuration.The surgical system further comprises a third drive system configured toperform a third end effector function. The third drive system isdrivable by the drive electric motor when the shifter electric motor isin the third configuration. The second drive system and the third drivesystem are not drivable by the drive electric motor when the shifterelectric motor is in the first configuration. The first drive system andthe third drive system are not drivable by the drive electric motor whenthe shifter electric motor is in the second configuration. The firstdrive system and the second drive system are not drivable by the driveelectric motor when the shifter electric motor is in the thirdconfiguration.

Example 13

The surgical system of Example 12, wherein the housing comprises ahandle.

Example 14

The surgical system of Examples 12 or 13, wherein the housing isconfigured to be attached to a robotic surgical system.

Example 15

The surgical system of Example 14, further comprising the roboticsurgical system.

Example 16

A surgical system comprising a housing, a shaft extending from thehousing, an end effector extending from the shaft, a first driveelectric motor, a first shifter electric motor configurable in a firstconfiguration and a second configuration, and a first drive systemconfigured to perform a first end effector function. The first drivesystem is drivable by the first drive electric motor when the firstshifter electric motor is in the first configuration. The surgicalsystem further comprises a second drive system configured to perform asecond end effector function. The second drive system is drivable by thefirst drive electric motor when the first shifter electric motor is inthe second configuration. The second drive system is not drivable by thefirst drive electric motor when the first shifter electric motor is inthe first configuration. The first drive system is not drivable by thefirst drive electric motor when the first shifter electric motor is inthe second configuration. The surgical system further comprises a seconddrive electric motor, a second shifter electric motor, and a third drivesystem. The second shifter electric motor is configurable in a thirdconfiguration and a fourth configuration. The third drive system isconfigured to perform a third end effector function. The third drivesystem is drivable by the second drive electric motor when the secondshifter electric motor is in the third configuration. The surgicalsystem further comprises fourth drive system configured to perform afourth end effector function. The fourth drive system is drivable by thesecond drive electric motor when the second shifter electric motor is inthe fourth configuration. The fourth drive system is not drivable by thesecond drive electric motor when the second shifter electric motor is inthe third configuration. The third drive system is not drivable by thesecond drive electric motor when the second shifter electric motor is inthe fourth configuration.

Example 17

The surgical system of Example 16, wherein the housing comprises ahandle.

Example 18

The surgical system of Examples 16 or 17, wherein the housing isconfigured to be attached to a robotic surgical system.

Example 19

The surgical system of Example 18, further comprising the roboticsurgical system.

Example 20

The surgical system of Examples 16, 17, 18, or 19, wherein the firstdrive electric motor and the second drive electric motor are operable atthe same time.

Example 21

The surgical system of Examples 16, 17, 18, 19, or 20, wherein the firstdrive electric motor and the second drive electric motor are operable atdifferent times.

Example Set 3 Example 1

A surgical instrument comprising a handle, a shaft extending from thehandle, an end effector extending from the shaft, and a drive system.The drive system comprises an electric motor, a drive shaft operablycoupled to the electric motor, a motor control system in communicationwith the electric motor, and a strain gage circuit embedded in the driveshaft. The strain gage circuit is in signal communication with the motorcontrol system. The motor control system is configured to control theoperation of the electric motor to perform an end effector functionbased on a signal from the strain gage circuit.

Example 2

The surgical instrument of Example 1, wherein the strain gage circuit isconfigured to measure the strain in the drive shaft, and wherein themotor control system comprises a processor and an algorithm configuredto stop the electric motor when the measured strain exceeds apredetermined threshold.

Example 3

The surgical instrument of Example 2, wherein the drive system furthercomprises an actuator and an actuation sensor, wherein the actuationsensor is in communication with the motor control system, wherein theactuator is movable between an unactuated position and an actuatedposition, and wherein an actuation of the actuator re-starts theelectric motor after being stopped by the motor control system.

Example 4

The surgical instrument of Example 1, wherein the strain gage circuit isconfigured to measure the strain in the drive shaft, and wherein themotor control system comprises a processor and an algorithm configuredto slow the electric motor when the measured strain exceeds apredetermined threshold.

Example 5

The surgical instrument of Example 4, wherein the drive system furthercomprises an actuator and an actuation sensor, wherein the actuationsensor is in communication with the motor control system, wherein theactuator is movable between an unactuated position and an actuatedposition, and wherein an actuation of the actuator speeds up theelectric motor after being slowed by the motor control system.

Example 6

The surgical instrument of Examples 1, 2, 3, 4, or 5, further comprisingmeans for regulating the temperature of the strain gage circuit.

Example 7

The surgical instrument of Example 6, wherein the means is configured tominimize the temperature variations in the strain gage circuit relativeto a predetermined temperature.

Example 8

The surgical instrument of Example 7, wherein the predeterminedtemperature is independent of the ambient temperature surrounding thesurgical instrument.

Example 9

The surgical instrument of Example 6, wherein the means is configured tohold the temperature of the strain gage circuit at a constanttemperature.

Example 10

The surgical instrument of Example 9, wherein the constant temperatureis different than the ambient temperature surrounding the surgicalinstrument.

Example 11

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10,further comprising a transmitter and a receiver. The transmitter is insignal communication with the motor control system. The transmitter isconfigured to emit a wireless signal to a surgical instrument system.The receiver is in signal communication with the motor control system.The receiver is configured to receive a wireless signal from thesurgical instrument system.

Example 12

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or11, further comprising an articulation joint rotatably connecting theend effector to the shaft, wherein the end effector function comprisesrotating the end effector about the articulation joint, and wherein themotor control system is configured to stop the articulation of the endeffector when the strain in the drive shaft exceeds a threshold level.

Example 13

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or11, further comprising an articulation joint rotatably connecting theend effector to the shaft, wherein the end effector function comprisesrotating the end effector about the articulation joint, and wherein themotor control system is configured to stop the articulation of the endeffector when the measured strain in the drive shaft exceeds a thresholdlevel.

Example 14

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or11, further comprising an articulation joint rotatably connecting theend effector to the shaft, wherein the end effector function comprisesrotating the end effector about the articulation joint, and wherein themotor control system is configured to slow the articulation of the endeffector when the measured strain in the drive shaft exceeds a thresholdlevel.

Example 15

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or11, wherein the end effector comprises a rotatable jaw, wherein the endeffector function comprises rotating the jaw, and wherein the motorcontrol system is configured to stop the rotation of the jaw when themeasured strain in the drive shaft exceeds a threshold level.

Example 16

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or11, wherein the end effector comprises a rotatable jaw, wherein the endeffector function comprises rotating the jaw, and wherein the motorcontrol system is configured to slow the rotation of the jaw when themeasured strain in the drive shaft exceeds a threshold level.

Example 17

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or11, wherein the end effector comprises a tissue cutting member, whereinthe end effector function comprises displacing the tissue cutting memberthrough a cutting stroke, and wherein the motor control system isconfigured to stop the translation of the tissue cutting member when themeasured strain in the drive shaft exceeds a threshold level.

Example 18

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or11, wherein the end effector comprises a tissue cutting member, whereinthe end effector function comprises displacing the tissue cutting memberthrough a cutting stroke, and wherein the motor control system isconfigured to slow the translation of the tissue cutting member when themeasured strain in the drive shaft exceeds a threshold level.

Example 19

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15, 16, 17, or 18, wherein the end effector comprises astaple cartridge including staples removably stored therein.

Example 20

A surgical instrument comprising a handle, a shaft extending from thehandle, an end effector extending from the shaft, and a drive system.The drive system comprises an electric motor, a drive shaft operablycoupled to the electric motor, and a motor control system incommunication with the electric motor. The surgical instrument furthercomprises a strain gage circuit in signal communication with the motorcontrol system. The motor control system is configured to control theoperation of the electric motor to perform an end effector functionbased on a signal from the strain gage circuit.

Example 21

A surgical system comprising a housing, a shaft extending from thehousing, an end effector extending from the shaft, and a drive system.The drive system comprises an electric motor, a drive shaft operablycoupled to the electric motor, and a motor control system incommunication with the electric motor. The surgical system furthercomprises a strain gage circuit in signal communication with the motorcontrol system. The motor control system is configured to control theoperation of the electric motor to perform an end effector functionbased on a signal from the strain gage circuit.

Example 22

The surgical system of Example 21, further comprising a forcemeasurement circuit in signal communication with the motor controlsystem, wherein the motor control system is configured to control theoperation of the electric motor to perform the end effector functionbased on a signal from the force measurement circuit.

Example 23

The surgical system of Example 21, further comprising a forcemeasurement circuit in signal communication with the motor controlsystem, wherein the motor control system is configured to control theoperation of the electric motor to perform a different end effectorfunction based on a signal from the force measurement circuit.

Example 24

The surgical system of Examples 22 or 23, wherein the force measurementcircuit comprises a spring element.

Example 25

A surgical system comprising a first instrument and a second instrument.The first instrument comprises a strain gage circuit and a transmitterin communication with the strain gage circuit. The second instrumentcomprises an electric motor, a drive shaft operably coupled to theelectric motor, and a motor control system in communication with theelectric motor and the transmitter. The motor control system isconfigured to control the operation of the electric motor based on asignal from the strain gage circuit.

Example 26

The surgical system of Example 25, further comprising a surgical datahub, wherein the motor control system is in communication with thetransmitter via the surgical data hub.

Example Set 4 Example 1

A surgical instrument comprising a handle and a shaft assembly extendingfrom the handle. The handle comprises a housing, a circuit boardpositioned in the housing, and a port defined in the housing. Thecircuit board comprises an electrical connector. The port comprises aseal. The seal comprises a self-sealing aperture. The port is configuredto permit a communications probe to be inserted through the self-sealingaperture to engage the electrical connector.

Example 2

The surgical instrument of Example 1, wherein the circuit boardcomprises a flex circuit mounted to the housing.

Example 3

The surgical instrument of Example 2, further comprising a secondcircuit board in communication with the flex circuit, wherein the secondcircuit board comprises a laminate circuit board.

Example 4

The surgical instrument of Example 3, wherein the flex circuit conductselectrical currents below a threshold amperage but not above thethreshold amperage, and wherein the laminate circuit board conductselectrical currents above the threshold amperage.

Example 5

The surgical instrument of Example 1, wherein the circuit boardcomprises a first circuit board, wherein the surgical instrument furthercomprises a second circuit board, wherein the housing comprises a cardslot defined therein, and wherein the second circuit board comprises acard removably retained in the card slot.

Example 6

The surgical instrument of Example 5, wherein the first circuit boardconducts electrical currents below a threshold amperage but not abovethe threshold amperage, and wherein the second circuit board conductselectrical currents above the threshold amperage.

Example 7

The surgical instrument of Examples 5 or 6, further comprisingelectrical contacts in the card slot, wherein the electrical contactsplace the second circuit board in communication with the first circuitboard when the second circuit board is seated in the card slot.

Example 8

The surgical instrument of Example 1, wherein the circuit boardcomprises a first circuit board, wherein the surgical instrument furthercomprises a second circuit board, wherein the first circuit boardconducts electrical currents below a threshold amperage but not abovethe threshold amperage, wherein the second circuit board conductselectrical currents above the threshold amperage, wherein the surgicalinstrument further comprises an electric motor, and wherein the secondcircuit board comprises a motor controller configured to control theelectric motor.

Example 9

The surgical instrument of Example 1, wherein the circuit boardcomprises a first circuit board, wherein the surgical instrument furthercomprises a second circuit board, wherein the first circuit boardconducts electrical currents below a threshold amperage but not abovethe threshold amperage, wherein the second circuit board conductselectrical currents above the threshold amperage, wherein the surgicalinstrument further comprises an RF generator, and wherein the secondcircuit board comprises a controller configured to control the RFgenerator.

Example 10

The surgical instrument of Example 1, wherein the circuit boardcomprises a first circuit board, wherein the surgical instrument furthercomprises a second circuit board, wherein the first circuit boardconducts electrical currents below a threshold amperage but not abovethe threshold amperage, wherein the second circuit board conductselectrical currents above the threshold amperage, wherein the surgicalinstrument further comprises a transducer configured to convertelectrical energy into mechanical energy, and wherein the second circuitboard comprises a controller configured to control the transducer.

Example 11

The surgical instrument of Example 1, wherein the circuit boardcomprises electrical traces printed on the housing.

Example 12

The surgical instrument of Example 11, wherein the circuit board furthercomprises solid state components surface mounted on the electricaltraces.

Example 13

The surgical instrument of Example 1, wherein the circuit boardcomprises electrical traces embedded in the housing, and wherein thehousing has been etched to at least partially expose the electricaltraces.

Example 14

The surgical instrument of Example 1, wherein the circuit boardcomprises a flex circuit embedded in the housing.

Example 15

The surgical instrument of Examples 2 or 14, further comprising a secondcircuit board in communication with the flex circuit, wherein the secondcircuit board comprises a laminate circuit board.

Example 16

The surgical instrument of Example 15, wherein the flex circuit conductselectrical currents below a threshold amperage but not above thethreshold amperage, and wherein the laminate circuit board conductselectrical currents above the threshold amperage.

Example 17

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15, or 16, further comprising a staple cartridge includingstaples removably stored therein.

Example 18

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15, 16, or 17, wherein the port is comprised of anelastomeric material.

Example 19

A surgical instrument comprising a handle housing, a first circuit boardembedded in the handle housing, and a second circuit board incommunication with the first circuit board. The first circuit boardconducts electrical currents below a threshold amperage but not abovethe threshold amperage. The second circuit board conducts electricalcurrents above the threshold amperage.

Example 20

The surgical instrument of Example 19, wherein the first circuit boardcomprises a flex circuit.

Example 21

The surgical instrument of Examples 19 or 20, wherein the handle housingcomprises a card slot defined therein, and wherein the second circuitboard comprises a card removably retained in the card slot.

Example 22

The surgical instrument of Examples 19, 20, or 21, further comprising anelectric motor, wherein the second circuit board comprises a motorcontroller configured to control the electric motor.

Example 23

The surgical instrument of Examples 19, 20, 21, or 22, furthercomprising an RF generator, wherein the second circuit board comprises acontroller configured to control the RF generator.

Example 24

The surgical instrument of Examples 19, 20, 21, or 22, furthercomprising a transducer configured to convert electrical energy intomechanical energy, wherein the second circuit board comprises acontroller configured to control the transducer.

Example 25

The surgical instrument of Examples 19, 20, 21, 22, 23, or 24, whereinthe first circuit board comprises electrical traces printed on thehandle housing.

Example 26

The surgical instrument of Examples 25 or 26, wherein the first circuitboard further comprises solid state components surface mounted on theelectrical traces.

Example 27

The surgical instrument of Examples 25 or 26, wherein the handle housinghas been etched to at least partially expose the electrical traces.

Example 28

The surgical instrument of Examples 19, 20, 21, 22, 23, 24, 25, 26, or27, further comprising a port defined in the handle housing, wherein theport comprises a seal, wherein the seal comprises a self-sealingaperture, wherein the first circuit board comprises an electricalcontact, and wherein the port is configured to permit a communicationsprobe to be inserted through the self-sealing aperture to engage theelectrical contact.

Example 29

A surgical instrument comprising a handle housing. The handle housingcomprises a rotation interface and an electric interface defined on therotation interface. The handle housing has been etched to at leastpartially expose the electrical interface. The surgical instrumentfurther comprises a shaft rotatably mounted to the handle housing at therotation interface. The shaft comprises electrical contacts engaged withthe electrical interface.

Example 30

The surgical instrument of Example 29, wherein the electrical interfacecomprises a flex circuit.

Example Set 5 Example 1

A surgical instrument handle comprising a housing, a control circuitpositioned in the housing, a button shell, and a flex circuit at leastpartially embedded in the button shell. The flex circuit is inelectrical communication with the control circuit.

Example 2

The surgical instrument handle of Example 1, wherein the button shellhas been etched to expose at least a portion of the flex circuit.

Example 3

The surgical instrument handle of Examples 1 or 2, wherein the buttonshell is molded over at least a portion of the flex circuit.

Example 4

The surgical instrument handle of Examples 1, 2, or 3, wherein thebutton shell and the housing comprise an assembly.

Example 5

The surgical instrument handle of Examples 1, 2, 3, or 4, wherein thebutton shell is integrally-formed with the housing.

Example 6

The surgical instrument handle of Examples 1, 2, 3, 4, or 5, wherein theflex circuit comprises a capacitive switch element.

Example 7

The surgical instrument handle of Example 6, wherein the button shellcomprises an outer surface accessible by a user of the surgicalinstrument handle, wherein the capacitive switch element is mounted tothe outer surface.

Example 8

The surgical instrument handle of Examples 1, 2, 3, 4, or 5, wherein theflex circuit comprises a force-sensitive piezoelectric switch element.

Example 9

The surgical instrument handle of Example 8, wherein the button shellcomprises an outer surface accessible by a user of the surgicalinstrument handle, wherein the force-sensitive piezoelectric switchelement is mounted to the outer surface.

Example 10

The surgical instrument handle of Examples 1, 2, 3, 4, or 5, wherein theflex circuit comprises a strain gage.

Example 11

The surgical instrument handle of Example 10, wherein the strain gage iscontained within the button shell.

Example 12

The surgical instrument handle of Examples 1, 2, 3, 4, or 5, wherein thebutton shell comprises a compliant section configured to permit thebutton shell to observably deflect when depressed by a user of thesurgical instrument handle.

Example 13

The surgical instrument handle of Example 12, wherein the flex circuitcomprises a switch positioned adjacent the button shell such that thebutton shell contacts the switch when the button shell is deflected bythe user.

Example 14

The surgical instrument handle of Examples 12 or 13, wherein the buttonshell comprises a living hinge.

Example 15

The surgical instrument handle of Examples 12 or 13, wherein the buttonshell comprises scoring configured to permit the button shell toobservably deflect.

Example 16

The surgical instrument handle of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14, or 15, wherein the button shell is constructed toresist observable deflection when depressed by the user of the surgicalinstrument handle.

Example 17

The surgical instrument handle of Example 16, wherein the controlcircuit comprises a haptic feedback generator, and wherein the controlcircuit actuates the haptic feedback generator when the button shell isdepressed.

Example 18

The surgical instrument handle of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14, 15, 16, or 17, wherein the housing and the buttonshell are comprised of the same material.

Example 19

The surgical instrument handle of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14, 15, 16, or 17, wherein the housing and the buttonshell are comprised of different materials.

Example 20

A surgical instrument comprising a housing, a control circuit positionedin the housing, a button shell, and an actuation circuit formed with thebutton shell. The actuation circuit is in electrical communication withthe control circuit.

Example 21

The surgical instrument of Example 20, wherein the actuation circuit isat least partially embedded in the button shell.

Example 22

The surgical instrument of Example 20, wherein the actuation circuit isat least partially attached to the button shell.

Example 23

The surgical instrument of Example 20, wherein the actuation circuit isat least partially printed on the button shell.

Example 24

The surgical instrument of Examples 20, 21, 22, or 23, wherein theactuation circuit comprises electrical traces and surface mountcomponents connected to the electrical traces.

Example 25

A surgical instrument comprising a housing, a control circuit, and abutton wall. The control circuit is at least partially formed with thebutton wall.

Example 26

The surgical instrument of Example 25, wherein the control circuit is atleast partially embedded in the button wall.

Example 27

The surgical instrument of Example 25, wherein the control circuit is atleast partially attached to the button wall.

Example 28

The surgical instrument of Example 25, wherein the control circuit is atleast partially printed on the button wall.

Example 29

The surgical instrument of Examples 25, 26, 27, or 28, wherein thecontrol circuit comprises electrical traces and surface mount componentsconnected to the electrical traces.

Example Set 6 Example 1

A surgical instrument comprising an electric motor and a controlcircuit. The control circuit comprises a plurality of logic gates and amonostable multivibrator connected to a first one of the logic gates.The control circuit is configured to alter a rate of action of afunction of the surgical instrument by controlling a speed of rotationof the electric motor based on a sensed parameter.

Example 2

The surgical instrument of Example 1, wherein the plurality of logicgates includes at least one of the following; (1) an AND gate, (2) an ORgate, and (3) an inverter gate.

Example 3

The surgical instrument of Examples 1 or 2, wherein the monostablemultivibrator comprises a retriggerable monostable multivibrator.

Example 4

The surgical instrument of Examples 1, 2, or 3, wherein the function ofthe surgical instrument comprises an articulation of an end effector ofthe surgical instrument.

Example 5

The surgical instrument of Examples 1, 2, 3, or 4, wherein the rate ofaction comprises a speed of an articulation of an end effector away froma longitudinal axis of a shaft of the surgical instrument.

Example 6

The surgical instrument of Example 5, wherein the speed of thearticulation is slowed as the end effector passes through a zone definedaround a centered state of a shaft of the surgical instrument.

Example 7

The surgical instrument of Examples 1, 2, 3, 4, 5, or 6, wherein thesensed parameter comprises a sensed position of an end effector relativeto a longitudinal axis of a shaft of the end effector.

Example 8

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, or 7, wherein thesensed parameter comprises a state of a switching device.

Example 9

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, or 8, whereinthe control circuit further comprises an asynchronous counter connectedto the monostable multivibrator.

Example 10

The surgical instrument of Example 9, wherein the asynchronous countercomprises a ripple counter.

Example 11

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10,further comprising a sensing device connected to the monostablemultivibrator.

Example 12

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or11, further comprising a motor controller configured to control thespeed of rotation of the electric motor.

Example 13

A surgical instrument comprising a flexible circuit comprising at leasttwo conductors. The flexible circuit is configured to transferelectrical power within the flexible circuit, carry a signal within theflexible circuit, and provide a secondary function.

Example 14

The surgical instrument of Example 13, wherein the flexible circuitcomprises a multilayer flexible circuit.

Example 15

The surgical instrument of Examples 12 or 13, wherein the at least twoconductors comprises a twisted pair of conductors which overlap oneanother at regular intervals.

Example 16

The surgical instrument of Example 15, wherein the twisted pair ofconductors are configured to mitigate interference from anelectromagnetic field from an external source.

Example 17

The surgical instrument of Examples 13, 14, 15, or 16, wherein the atleast two conductors comprises first and second pluralities ofconductors.

Example 18

The surgical instrument of Example 17, wherein the flexible circuitfurther comprises an electromagnetic shield which surrounds the firstand second pluralities of conductors.

Example 19

The surgical instrument of Examples 13, 14, 15, 16, 17, or 18, whereinthe secondary function comprises electromagnetic shielding.

Example 20

The surgical instrument of Examples 13, 14, 15, 16, 17, or 18, whereinthe secondary function comprises short-circuit protection.

Example 21

The surgical instrument of Examples 13, 14, 15, 16, 17, or 18, whereinthe secondary function comprises contamination detection.

Example Set 7 Example 1

A surgical instrument comprising a drive system and a control circuit.The drive system comprises an electric motor. The control circuitcomprises an acoustic sensor. The control circuit is configured toutilize a parameter of the drive system measured by the acoustic sensorto control a speed of the electric motor.

Example 2

The surgical instrument of Example 1, wherein the drive system furthercomprises a gear box and a drive train.

Example 3

The surgical instrument of Examples 1 or 2, wherein the control circuitfurther comprises at least one of the following; (1) a fast Fouriertransform circuit and (2) a fast Fourier transform algorithm executableby a processor of the control circuit.

Example 4

The surgical instrument of Examples 1, 2, or 3, wherein the controlcircuit is further configured to determine a degradation of the drivesystem.

Example 5

The surgical instrument of Example 4, wherein the control circuit isfurther configured to adjust a motor control algorithm in response tothe determined degradation of the drive system.

Example 6

The surgical instrument of Example 5, wherein the motor controlalgorithm, when executed by the surgical instrument, is configured toadjust at least one of the following; (1) the speed of the electricmotor, (2) a motor speed command signal provided by a motor controllerof the surgical instrument, (3) a voltage applied to the electric motor,(4) a pulse width modulation duty cycle, and (5) a current limit of amotor controller of the surgical instrument.

Example 7

The surgical instrument of Examples 1, 2, 3, 4, 5, or 6, wherein thecontrol circuit is further configured to provide an indication of animpending failure of the surgical instrument.

Example 8

A surgical instrument comprising a drive system and a control circuit.The drive system comprises an electric motor. The control circuitcomprises an acoustic sensor. The control circuit is configured toutilize a parameter of the drive system measured by the acoustic sensorto control a torque applied by the electric motor.

Example 9

The surgical instrument of Example 8, wherein the drive system furthercomprises a gear box and a drive train.

Example 10

The surgical instrument of Examples 8 or 9, wherein the control circuitfurther comprises a fast Fourier transform circuit.

Example 11

The surgical instrument of Examples 8, 9, or 10, wherein the controlcircuit is further configured to determine a degradation of the drivesystem.

Example 12

The surgical instrument of Example 11, wherein the control circuit isfurther configured to adjust a motor control algorithm in response tothe determined degradation of the drive system.

Example 13

The surgical instrument of Example 12, wherein the motor controlalgorithm, when executed by the surgical instrument, is configured toadjust at least one of the following; (1) the speed of the electricmotor, (2) a motor speed command signal provided by a motor controllerof the surgical instrument, (3) a voltage applied to the electric motor,(4) a pulse width modulation duty cycle, and (5) a current limit of amotor controller of the surgical instrument.

Example 14

The surgical instrument of Examples 8, 9, 10, 11, 12, or 13, wherein thecontrol circuit is further configured to provide an indication of animpending failure of the surgical instrument.

Example 15

A surgical system comprising a surgical instrument and a surgical hubsystem. The surgical instrument comprises a drive system and a controlcircuit. The drive system comprises an electric motor. The controlcircuit comprises a sensing device. The control circuit is configured toutilize a parameter of the drive system sensed by the sensing device tocontrol a speed of the electric motor. The surgical hub system is incommunication with the surgical instrument. The surgical hub system isconfigured to supply a second parameter to the control circuit. Thecontrol circuit is further configured to utilize the second parameter tomodify an operation of the surgical instrument.

Example 16

The surgical system of Example 15, wherein the sensing device comprisesat least one of the following; (1) an acoustic sensor, (2) a vibrationsensor, and (3) an accelerometer.

Example 17

The surgical system of Examples 15 or 16, wherein the control circuitfurther comprises a fast Fourier transform circuit.

Example 18

The surgical system of Examples 15, 16, or 17, wherein the secondparameter comprises the presence of a previous stapling line in thetissue of the patient.

Example 19

The surgical system of Examples 15, 16, or 17, wherein the secondparameter comprises the presence of a gastric band in the tissue of thepatient.

Example 20

The surgical system of Examples 15, 16, or 17, wherein the secondparameter comprises the presence of scarred tissue from a previoussurgical procedure.

Example 21

The surgical system of Examples 15, 16, 17, 18, 19, or 20, wherein thesurgical hub system is further configured to predict a failure of thesurgical instrument.

Example 22

The surgical system of Examples 15, 16, 17, 18, 19, or 20, wherein thesurgical hub system is further configured to provide a notification of apredicted failure of the surgical instrument.

Example 23

The surgical system of Examples 15, 16, 17, 18, 19, or 20, wherein thesurgical hub system is further configured to communicate a predictedfailure of the surgical instrument to the surgical instrument.

Example Set 8 Example 1

A surgical instrument comprising a body, a shaft, and a control circuitcomprising at least one sensing device. The control circuit isconfigured to determine a presence of another surgical instrumentproximate to the surgical instrument within an environment of a surgicalprocedure.

Example 2

The surgical instrument of Example 1, wherein the surgical instrumentcomprises a monopolar surgical instrument.

Example 3

The surgical instrument of Examples 1 or 2, wherein the at least onesensing device comprises a passive sensing device.

Example 4

The surgical instrument of Example 3, wherein the passive sensing deviceis configured to be activated by a magnetic field associated with theanother surgical instrument.

Example 5

The surgical instrument of Examples 3 or 4, wherein the passive sensingdevice is configured to be activated by an electric field associatedwith the another surgical instrument.

Example 6

The surgical instrument of Example 2, wherein the at least one sensingdevice comprises a continuity sensor and is positioned on at least oneof the following; (1) a body of the monopolar surgical instrument and(2) a shaft of the monopolar surgical instrument.

Example 7

The surgical instrument of Examples 1, 2, 3, 4, 5, or 6, wherein the atleast one sensing device comprises a proximity sensor configured todetect the presence of the another surgical instrument within theenvironment of the surgical procedure.

Example 8

The surgical instrument of Example 7, wherein the proximity sensorcomprises one of the following; (1) an inductive proximity sensor and(2) a capacitive proximity sensor.

Example 9

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, or 8, whereinthe at least one sensing device comprises an electrical sensing grid.

Example 10

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, or 9,wherein the control circuit is further configured to determineelectrical continuity within the surgical instrument.

Example 11

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10,wherein the control circuit is further configured to determineelectrical continuity within an electrical circuit configured to carryelectrosurgical energy.

Example 12

A surgical instrument comprising a transmitter, a receiver, and acontrol circuit. The transmitter is configured to transmit a signal. Thereceiver is configured to receive a reflected signal associated with thetransmitted signal. The control circuit is configured to determine aproximity of another surgical instrument to the surgical instrumentbased on the reflected signal.

Example 13

The surgical instrument of Example 12, wherein the transmitter comprisesa magnetic transmitter.

Example 14

The surgical instrument of Examples 12 or 13, wherein the transmitter isfurther configured to generate random sequenced on-off pulses.

Example 15

The surgical instrument of Examples 12, 13, or 14, wherein at least oneof the following forms a part of a flexible circuit; (1) the transmitterand (2) the receiver.

Example 16

A surgical instrument comprising a transmitter and a transducer. Thetransmitter is configured to transmit a signal. The transducer isconfigured to sense a primary magnetic field associated with thetransmitter. The surgical instrument further comprises means fordetermining a proximity of another surgical instrument to the surgicalinstrument based on a condition of the primary magnetic field.

Example 17

The surgical instrument of Example 16, wherein the transmitter comprisesa magnetic transmitter.

Example 18

The surgical instrument of Examples 16 or 17, wherein the transducercomprises a Hall-effect sensor.

Example 19

The surgical instrument of Examples 16, 17, or 18, wherein the conditioncomprises one of the following; (1) an unaffected condition which isindicative of there being no object comprising a metal proximate to thesurgical instrument and (2) an affected condition which is indicative ofthere being an object comprising a metal proximate to the surgicalinstrument.

Example 20

The surgical instrument of Example 19, wherein the object comprises theanother surgical instrument.

Example Set 9 Example 1

A surgical instrument comprising a shaft, a sensing array positionedwithin the shaft, and a detection circuit electrically coupled to thesensing array. The detection circuit is configured to determine when afluid originating from an environment external to the shaft is presentwithin the shaft.

Example 2

The surgical instrument of Example 1, wherein the sensing array forms apart of a flexible circuit.

Example 3

The surgical instrument of Examples 1 or 2, wherein the sensing arraycomprises first and second sensing devices.

Example 4

The surgical instrument of Example 3, wherein the first and secondsensing devices comprise electrically conductive electrodes.

Example 5

The surgical instrument of Example 3, wherein the sensing array furthercomprises third and fourth sensing devices.

Example 6

The surgical instrument of Example 3, further comprising an electricallyinsulative material positioned between the first and second sensingdevices.

Example 7

The surgical instrument of Example 6, wherein the electricallyinsulative material forms a part of a flexible circuit.

Example 8

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, or 7, furthercomprising an absorption material positioned within the shaft.

Example 9

The surgical instrument of Example 8, wherein the absorption materialcomprises a ring of absorption material which is concentric with theshaft.

Example 10

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, or 9,further comprising an electrical circuit electrically connected to thesensing array, wherein the electrical circuit is configured to determinewhether an amount of the fluid within the shaft is greater than athreshold amount.

Example 11

The surgical instrument of Example 10, wherein the electrical circuitcomprises at least one comparator.

Example 12

The surgical instrument of Example 10, wherein the electrical circuitcomprises a plurality of comparators.

Example 13

The surgical instrument of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,or 12, further comprising a control circuit couplable to the detectioncircuit, wherein the control circuit is configured to adjust anoperation of the surgical instrument based on a signal from thedetection circuit.

Example 14

A surgical instrument comprising a sensing device and a control circuit.The sensing device is configured to sense an atmospheric pressure. Thecontrol circuit is configured to determine an altitude of the surgicalinstrument based on the sensed atmospheric pressure. The control circuitis further configured to adjust at least one of the following based onthe sensed atmospheric pressure; (1) a threshold utilized by the controlcircuit and (2) a control parameter of the surgical instrument.

Example 15

The surgical instrument of Example 14, wherein the threshold comprisesat least one of the following; (1) a temperature threshold and (2) anenergy threshold.

Example 16

The surgical instrument of Examples 14 or 15, wherein the controlparameter comprises a motor speed.

Example 17

The surgical instrument of Examples 14, 15, or 16, wherein the controlcircuit is further configured to determine a de-rating factor based onthe sensed atmospheric pressure.

Example 18

A surgical instrument comprising a handle assembly, at least one sensingdevice, and a control circuit. The handle assembly comprises a housing.The at least one sensing device is positioned within the housing and isconfigured to measure a temperature. The control circuit is configuredto determine whether at least one of the following is operating in adanger zone based on the measured temperature; (1) an electricalcomponent of the surgical instrument and (2) a sub-assembly of thesurgical instrument.

Example 19

The surgical instrument of Example 18, wherein the at least one sensingdevice forms a part of a flexible circuit.

Example 20

The surgical instrument of Examples 18 or 19, wherein the controlcircuit is further configured to adjust an operation of the surgicalinstrument based on the measured temperature.

The surgical instrument systems described herein are motivated by anelectric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In certain instances,the motors disclosed herein may comprise a portion or portions of arobotically controlled system. U.S. patent application Ser. No.13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example,discloses several examples of a robotic surgical instrument system ingreater detail, the entire disclosure of which is incorporated byreference herein.

The surgical instrument systems described herein can be used inconnection with the deployment and deformation of staples. Variousembodiments are envisioned which deploy fasteners other than staples,such as clamps or tacks, for example. Moreover, various embodiments areenvisioned which utilize any suitable means for sealing tissue. Forinstance, an end effector in accordance with various embodiments cancomprise electrodes configured to heat and seal the tissue. Also, forinstance, an end effector in accordance with certain embodiments canapply vibrational energy to seal the tissue. In addition, variousembodiments are envisioned which utilize a suitable cutting means to cutthe tissue.

The entire disclosures of:

-   -   U.S. patent application Ser. No. 11/013,924, entitled TROCAR        SEAL ASSEMBLY, now U.S. Pat. No. 7,371,227;    -   U.S. patent application Ser. No. 11/162,991, entitled        ELECTROACTIVE POLYMER-BASED ARTICULATION MECHANISM FOR GRASPER,        now U.S. Pat. No. 7,862,579;    -   U.S. patent application Ser. No. 12/364,256, entitled SURGICAL        DISSECTOR, now U.S. Patent Application Publication No.        2010/0198248;    -   U.S. patent application Ser. No. 13/536,386, entitled EMPTY CLIP        CARTRIDGE LOCKOUT, now U.S. Pat. No. 9,282,974;    -   U.S. patent application Ser. No. 13/832,786, entitled CIRCULAR        NEEDLE APPLIER WITH OFFSET NEEDLE AND CARRIER TRACKS, now U.S.        Pat. No. 9,398,905;    -   U.S. patent application Ser. No. 12/592,174, entitled APPARATUS        AND METHOD FOR MINIMALLY INVASIVE SUTURING, now U.S. Pat. No.        8,123,764;    -   U.S. patent application Ser. No. 12/482,049, entitled ENDOSCOPIC        STITCHING DEVICES, now U.S. Pat. No. 8,628,545;    -   U.S. patent application Ser. No. 13/118,241, entitled SURGICAL        STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT        ARRANGEMENTS, now U.S. Pat. No. 9,072,535;    -   U.S. patent application Ser. No. 11/343,803, entitled SURGICAL        INSTRUMENT HAVING RECORDING CAPABILITIES, now U.S. Pat. No.        7,845,537;    -   U.S. patent application Ser. No. 14/200,111, entitled CONTROL        SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,629,629;    -   U.S. patent application Ser. No. 14/248,590, entitled MOTOR        DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now        U.S. Pat. No. 9,826,976;    -   U.S. patent application Ser. No. 14/813,242, entitled SURGICAL        INSTRUMENT COMPRISING SYSTEMS FOR ASSURING THE PROPER SEQUENTIAL        OPERATION OF THE SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2017/0027571;    -   U.S. patent application Ser. No. 14/248,587, entitled POWERED        SURGICAL STAPLER, now U.S. Pat. No. 9,867,612;    -   U.S. patent application Ser. No. 12/945,748, entitled SURGICAL        TOOL WITH A TWO DEGREE OF FREEDOM WRIST, now U.S. Pat. No.        8,852,174;    -   U.S. patent application Ser. No. 13/297,158, entitled METHOD FOR        PASSIVELY DECOUPLING TORQUE APPLIED BY A REMOTE ACTUATOR INTO AN        INDEPENDENTLY ROTATING MEMBER, now U.S. Pat. No. 9,095,362;

International Application No. PCT/US2015/023636, entitled SURGICALINSTRUMENT WITH SHIFTABLE TRANSMISSION, now International PatentPublication No. WO 2015/153642 A1;

International Application No. PCT/US2015/051837, entitled HANDHELDELECTROMECHANICAL SURGICAL SYSTEM, now International Patent PublicationNo. WO 2016/057225 A1;

-   -   U.S. patent application Ser. No. 14/657,876, entitled SURGICAL        GENERATOR FOR ULTRASONIC AND ELECTROSURGICAL DEVICES, U.S.        Patent Application Publication No. 2015/0182277;    -   U.S. patent application Ser. No. 15/382,515, entitled MODULAR        BATTERY POWERED HANDHELD SURGICAL INSTRUMENT AND METHODS        THEREFOR, U.S. Patent Application Publication No. 2017/0202605;    -   U.S. patent application Ser. No. 14/683,358, entitled SURGICAL        GENERATOR SYSTEMS AND RELATED METHODS, U.S. Pat. No. 10,117,702;    -   U.S. patent application Ser. No. 14/149,294, entitled HARVESTING        ENERGY FROM A SURGICAL GENERATOR, U.S. Pat. No. 9,795,436;    -   U.S. patent application Ser. No. 15/265,293, entitled TECHNIQUES        FOR CIRCUIT TOPOLOGIES FOR COMBINED GENERATOR, U.S. Patent        Application Publication No. 2017/0086910; and    -   U.S. patent application Ser. No. 15/265,279, entitled TECHNIQUES        FOR OPERATING GENERATOR FOR DIGITALLY GENERATING ELECTRICAL        SIGNAL WAVEFORMS AND SURGICAL INSTRUMENTS, U.S. Patent        Application Publication No. 2017/0086914, are hereby        incorporated by reference herein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdo not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical instrument handle, comprising: ahousing; a control circuit positioned in said housing; a button shell;and a flex circuit at least partially embedded in said button shell,wherein said flex circuit is in electrical communication with saidcontrol circuit.
 2. The surgical instrument handle of claim 1, whereinsaid button shell has been etched to expose at least a portion of saidflex circuit.
 3. The surgical instrument handle of claim 1, wherein saidbutton shell is molded over at least a portion of said flex circuit. 4.The surgical instrument handle of claim 1, wherein said button shell andsaid housing comprise an assembly.
 5. The surgical instrument handle ofclaim 1, wherein said button shell is integrally-formed with saidhousing.
 6. The surgical instrument handle of claim 1, wherein said flexcircuit comprises a capacitive switch element.
 7. The surgicalinstrument handle of claim 6, wherein said button shell comprises anouter surface accessible by a user of the surgical instrument handle,wherein said capacitive switch element is mounted to said outer surface.8. The surgical instrument handle of claim 1, wherein said flex circuitcomprises a force-sensitive piezoelectric switch element.
 9. Thesurgical instrument handle of claim 8, wherein said button shellcomprises an outer surface accessible by a user of the surgicalinstrument handle, wherein said force-sensitive piezoelectric switchelement is mounted to said outer surface.
 10. The surgical instrumenthandle of claim 1, wherein said flex circuit comprises a strain gage.11. The surgical instrument handle of claim 10, wherein said strain gageis contained within said button shell.
 12. The surgical instrumenthandle of claim 1, wherein said button shell comprises a compliantsection configured to permit said button shell to observably deflectwhen depressed by a user of said surgical instrument handle.
 13. Thesurgical instrument handle of claim 12, wherein said flex circuitcomprises a switch positioned adjacent said button shell such that saidbutton shell contacts said switch when said button shell is deflected bythe user.
 14. The surgical instrument handle of claim 12, wherein saidbutton shell comprises a living hinge.
 15. The surgical instrumenthandle of claim 12, wherein said button shell comprises scoringconfigured to permit said button shell to observably deflect.
 16. Thesurgical instrument handle of claim 1, wherein said button shell isconstructed to resist observable deflection when depressed by the userof the surgical instrument handle.
 17. The surgical instrument handle ofclaim 16, wherein said control circuit comprises a haptic feedbackgenerator, and wherein said control circuit actuates said hapticfeedback generator when said button shell is depressed.
 18. The surgicalinstrument handle of claim 1, wherein said housing and said button shellare comprised of the same material.
 19. The surgical instrument handleof claim 1, wherein said housing and said button shell are comprised ofdifferent materials.
 20. The surgical instrument handle of claim 1,wherein said button shell defines an external surface of a push buttoncontrol.
 21. The surgical instrument handle of claim 1, furthercomprising an articulation drive motor, and wherein said button shell isactuatable to operate said articulation drive motor.
 22. A surgicalinstrument, comprising: a housing; a control circuit positioned in saidhousing; a button shell; and an actuation circuit formed with saidbutton shell, wherein said actuation circuit is at least partiallyembedded in said button shell, and wherein said actuation circuit is inelectrical communication with said control circuit.
 23. The surgicalinstrument of claim 22, wherein said actuation circuit is at leastpartially attached to said button shell.
 24. The surgical instrument ofclaim 22, wherein said actuation circuit is at least partially printedon said button shell.
 25. The surgical instrument of claim 24, whereinsaid actuation circuit comprises electrical traces and surface mountcomponents connected to said electrical traces.
 26. A surgicalinstrument, comprising: a housing; a control circuit; and a button wall,wherein said control circuit is at least partially formed with saidbutton wall, and wherein said control circuit is at least partiallyembedded in said button wall.
 27. The surgical instrument of claim 26,wherein said control circuit is at least partially attached to saidbutton wall.
 28. The surgical instrument of claim 26, wherein saidcontrol circuit is at least partially printed on said button wall. 29.The surgical instrument of claim 28, wherein said control circuitcomprises electrical traces and surface mount components connected tosaid electrical traces.